Hypoid gear design method

ABSTRACT

A hypoid gear tooth surface design method, wherein normal lines and helical angles of two tooth surfaces are properly selected so as to position action limit curves (L 3Acc ) on the outer of the areas (R 2t  to R 2h ) where the tooth surfaces are formed, whereby undercut to a gear small end side can be prevented and, by setting the involute helicoids of two tooth surfaces on a pinion side to an equal lead, a pinion top land and a gear top land (z 2h   =0 ) can be made generally equal to each other in tooth lengthwise direction, such that sharpening of the top land can be prevented.

TECHNICAL FIELD

[0001] The present invention relates to a hypoid gear tooth surface design method.

BACKGROUND ART

[0002] The applicant of the application concerned has proposed a method for uniformly describing a tooth surface of a pair of gears in Japanese Patent Laid-Open Publication No. Hei 9-53702. That is, a method for describing a tooth surface, which can uniformly be used in various situations including for a pair of parallel axes gears, which is the most widely used configuration, and a pair of gears whose axes do not intersect and are not parallel with each other (skew position), has been shown. Furthermore, it has been shown that, in power transmission gearing, it is necessary that the path of contact of the tooth surfaces should be a straight line in order to reduce a fluctuation of a load applied to bearings supporting shafts of gears. In addition, it has been clarified that a configuration wherein at least one tooth surface is an involute helicoid and the other tooth surface is a conjugate surface satisfies the condition that a path of contact of the tooth surfaces should be a straight line. In the case of parallel axes gears, such as spur gears, helical gears, this conclusion is identical with a conclusion of a conventional design method.

[0003] Furthermore, conventional gear design methods for non-parallel axes gears have been empirically obtained.

[0004] In the case of non-parallel axes gears, it has not yet been clarified that there actually exists a pair of gears wherein one gear has an involute helicoidal tooth surface and the other gear has a conjugate tooth surface for the involute helicoidal tooth surface and, further, an efficient method for obtaining such a pair of tooth surfaces was unknown.

DISCLOSURE OF INVENTION

[0005] An object of the present invention is to provide a method for designing a gear set, in particular a gear set comprising a pair of gears whose axes do not intersect and which are not parallel with each other.

[0006] The present invention provides a design method for a pair of gears whose axes do not intersect and are not parallel with each other, such as hypoid gears. Hereinafter, a small diameter gear in a pair of hypoid gears is referred to as a pinion and a large diameter gear is referred to as a large gear. In this specification, hypoid gears include a pair of gears in which a pinion is a cylindrical gear having its teeth formed on a cylinder and a large gear is a so-called face gear having teeth on a surface perpendicular to an axis of a disk.

[0007] Tooth surfaces of a hypoid gear can be described by a method disclosed in Japanese Patent Laid-Open Publication No. Hei 9-53702 described above.

[0008] First, let us consider (a) a stationary coordinate system in which one of three orthogonal coordinate axes coincides with a rotation axis of the gear and one of other two coordinate axes coincides with a common perpendicular for the rotation axis of the gear and the rotation axis of the mating gear to be engaged with the gear, (b) a rotary coordinate system in which one of three orthogonal coordinate axes coincides with the axis of the stationary coordinate system that coincides with the rotation axis of the gear, the rotary coordinate system rotates about the coincided axis together with the gear, and other two coordinate axes of three orthogonal coordinate axes coincide with other two coordinate axes of the stationary coordinate system respectively when the rotation angle of the gear is 0, and (c) a parameter coordinate system in which the stationary coordinate system is rotated about the rotation axis of the gear so that one of other two coordinate axes of the stationary coordinate system becomes parallel with the plane of action of the gear, respectively. Next, in the parameter coordinate system, a path of contact of a pair of tooth surfaces of the gear and the mating gear which are engaging with each other during the rotation of the gears and an inclination angle of the common normal which is a normal at each point of contact for the pair of tooth surfaces are described in terms of a first function, in which a rotation angle of the gear is used as a parameter. Furthermore, in the stationary coordinate system, the path of contact and the inclination angle of the common normal are described respectively in terms of a second function, in which a rotation angle of the gear is used as a parameter, based on the first function and the relationship between the relative positions of the stationary coordinate system and the parameter coordinate system. Furthermore, the path of contact and the inclination angle of the common normal in the stationary coordinate system are acquired, respectively, and in the rotary coordinate system, a tooth profile is obtained by describing the path of contact and the inclination angle of the common normal, respectively, in terms of a third function, in which a rotation angle of the gear is used as a parameter, based on the second function and the relationship between the relative positions of the rotary coordinate system and the stationary coordinate system.

[0009] From the obtained tooth profile, the surface of action for the pair of tooth surfaces is obtained. In a gear pair wherein a tooth surface of one gear (first gear) is an involute helicoid and the other gear (second gear) has a tooth surface conjugated with the tooth surface of the first gear, in the obtained surface of action, a zone where effective contact of a pair of tooth surfaces is realized (hereinafter, referred to as an effective surface of action) is limited to a part of the obtained surface of action. First, the effective surface of action must exist between action limit curves which are orthogonal projections of the axes of the two gears on the surface of action. Further, the effective surface of action must exist on the root side of a surface generated by the top of the gear, that is, a trajectory surface of the top of the gear due to the rotation of the gear. Therefore, the effective surface of action must exist between the line of intersection of the face surface formed by the rotation of the top of the gear and the surface of action (hereinafter, referred to as a tip line) and the action limit curves. Therefore, it is preferable that the area enclosed by the action limit curves and the tip line (that is, the effective surface of action) exists at least over the whole facewidth of the gear. When the effective surface of action exists on only a part of the facewidth, the residual facewidth is not useful as a gear, and such a design is nonsensical, or at least wasteful.

[0010] Furthermore, in order to actually form gear teeth, it is necessary that the teeth have necessary strength. Specifically, a required thickness must be given to a tooth surface of a drive side and a tooth surface of a coast side, and a root must be thicker than a top in a normal cross section profile of a tooth. In order to make the root sufficiently thick, it is necessary to properly select an intersection angle of the respective paths of contact for the tooth surface of the drive side and the tooth surface of the coast side. It is empirically appropriate that the intersection angle of the respective paths of contact for the tooth surface of the drive side and the tooth surface of the coast side is selected to be in the range from 38° to 40°, which corresponds to the vertex angle in conventional racks. Furthermore, it is empirically appropriate that the line of contact in the drive side is selected so as to nearly coincide with one of the limiting paths of contact (g_(2z), g_(t), g_(1K)) described below.

[0011] In order to generate the tooth described above on the first gear, it is necessary to acquire a profile of an equivalent rack. It can be considered that the equivalent rack is a generalized rack for involute spur gears.

[0012] Furthermore, when the tooth surface of the second gear is obtained using the determined path of contact and the face surface of the second gear is given, the tip lines for both normal and coast sides are obtained and the distance between both tip lines can be obtained; a small distance indicates that the face surface width of the second gear is narrow.

[0013] The effective surface of action is likely to be insufficient at a small end of a large gear, and the distance between both tip lines of the second gear (face surface width) is likely to be insufficient at a large end. When the effective surface of action is insufficient at a small end side, a design reference point is shifted toward the small end side of the gear, and acquisition of the tooth profile and the effective surface of action are carried out again. Further, when the distance between both tip lines is insufficient at the large end side, a design reference point is shifted toward the large end side of the large gear, and acquisition of the tooth profile and the effective surface of action is carried out. When the effective surface of action is insufficient at a small end side, and at the same time, the distance between both tip lines is insufficient at the large end side, the facewidth is reduced.

[0014] The above design processes can be executed using a computer by describing the processes by a predetermined computer program. Input means for receiving specifications of gears and selection of variables and output means for outputting design results or calculated results until a midterm stage of the design processes are connected to the computer.

BRIEF DESCRIPTION OF DRAWINGS

[0015] [FIG. 1]

[0016]FIG. 1 is a schematic figure showing coordinate axes of respective coordinate systems, tooth surfaces of gears, tooth profiles, and a path of contact.

[0017] [FIG. 2]

[0018]FIG. 2 is a figure for explaining relationships between respective coordinate systems.

[0019] [FIG. 3]

[0020]FIG. 3 is a figure for explaining the obtaining of a path of contact and a tooth profile.

[0021] [FIG. 4]

[0022]FIG. 4 is a figure showing a path of contact and a tooth profile.

[0023] [FIG. 5]

[0024]FIG. 5 is a figure showing a concentrated load applied to a gear II and a relationship between the concentrated load and the bearing load.

[0025] [FIG. 6]

[0026]FIG. 6 is a figure showing a path of contact in a case wherein fluctuations of the bearing load are zero.

[0027] [FIG. 7]

[0028]FIG. 7 is a figure showing a relative rotation axis S and a coordinate system C_(S) severally for explaining a specific method for determining five variable values needed to be specified for obtaining a tooth profile from a path of contact (Hereinafter, referred to as a “variable determining method” simply).

[0029] [FIG. 8]

[0030]FIG. 8 is a figure showing a relative velocity V_(S) at a point C_(S) for explaining the aforesaid variable determining method.

[0031] [FIG. 9]

[0032]FIG. 9 is a figure showing a design reference point P₀, a relative velocity V_(rs0) and a path of contact g₀ severally together with planes S_(H), S_(S), S_(P) and S_(n) for explaining the aforesaid variable determining method.

[0033] [FIG. 10]

[0034]FIG. 10 is a figure showing a relationship between a relative velocity V_(rs) and the path of contact g₀ at a point P for explaining the aforesaid variable determining method.

[0035] [FIG. 11]

[0036]FIG. 11 is a figure showing the relative velocity V_(rs0) and the path of contact g₀ at the design reference point P₀ severally in the coordinate system C_(s) for explaining the aforesaid variable determining method.

[0037] [FIG. 12]

[0038]FIG. 12 is a figure showing the design reference point P₀ and the path of contact g₀ severally in coordinate systems O₂, O_(q2), O₁ and O_(q1) for explaining the aforesaid variable determining method.

[0039] [FIG. 13]

[0040]FIG. 13 is a figure showing a relationship among paths of contact g_(n0) (ψ₀φ_(n0)), g₀ (φ₁₀, ψ_(b10)) and g₀ (φ₂₀, ψ_(b20)) for explaining the aforesaid variable determining method.

[0041] [FIG. 14]

[0042]FIG. 14 is a figure showing the path of contact g₀ and a tooth profile II severally in the coordinate systems O₂ and O_(r2) for explaining the aforesaid variable determining method.

[0043] [FIG. 15]

[0044]FIG. 15 is a figure showing the path of contact g₀ and a tooth profile I severally in the coordinate systems O₁ and O_(r2) for explaining the aforesaid variable determining method.

[0045] [FIG. 16]

[0046]FIG. 16 is a figure showing a plane of action G₂₀ for explaining a specific method for determining a tooth surface from a tooth profile (Hereinafter, referred to simply as a “tooth surface determining method”).

[0047] [FIG. 17]

[0048]FIG. 17 is a figure showing an involute helicoid at a rotation angle θ₂ for explaining the aforesaid tooth surface determining method.

[0049] [FIG. 18]

[0050]FIG. 18 is a figure showing a common normal n_(m)(P_(m0) P_(m)) and a line of contact PP_(m) for explaining the aforesaid tooth surface determining method.

[0051] [FIG. 19]

[0052]FIG. 19 is a figure showing a relationship among points Q_(m0) (P_(m0)), Q_(m) (P_(m)), Q and P on the plane of action G₂₀ for explaining the aforesaid tooth surface determining method.

[0053] [FIG. 20]

[0054]FIG. 20 is a figure showing a point P_(m) and the common normal n_(m) severally in the coordinate systems O₁ and O_(q1) for explaining the aforesaid tooth surface determining method.

[0055] [FIG. 21]

[0056]FIG. 21 is a figure showing a group of pairs of gears which has the same involute helicoids for one member for explaining the aforesaid tooth surface determining method.

[0057] [FIG. 22]

[0058]FIG. 22 is a figure showing the specifications of a hypoid gear.

[0059] [FIG. 23]

[0060]FIG. 23 is a figure showing relationships among planes S_(H), S_(P), S_(n), S_(t) and W_(N) in a bevel gear and a hypoid gear.

[0061] [FIG. 24]

[0062]FIG. 24 is a figure showing a design reference perpendicular C_(n) and a limiting path g_(t) of a hypoid gear.

[0063] [FIG. 25]

[0064]FIG. 25 is a figure showing the plane S_(n) and an equivalent rack.

[0065] [FIG. 26]

[0066]FIG. 26 is a figure showing relationships among paths of contact g_(0D), g_(0C), limiting paths g_(2z), g_(t) and an equivalent rack.

[0067] [FIG. 27]

[0068]FIG. 27 is an oblique perspective figure showing a surface of action.

[0069] [FIG. 28]

[0070]FIG. 28 is a figure showing examples of an effective surface of action and an action limit curve of a hypoid gear, which is viewed to a negative direction along a z₁ axis in FIG. 27.

[0071] [FIG. 29]

[0072]FIG. 29 is a figure showing the examples of the effective surface of action and the action limit curve of the hypoid gear, which is viewed to a negative direction along a v₁ axis in FIG. 27.

[0073] [FIG. 30]

[0074]FIG. 30 is a figure showing the examples of the effective surface of action and the action limit curve of the hypoid gear, which is viewed to a negative direction along a u₁ axis in FIG. 27.

[0075] [FIG. 31]

[0076]FIG. 31 is a figure showing the examples of the effective surface of action and the action limit curve of the hypoid gear, which corresponds to FIG. 28 and shows a surface of action in a case where the base cylinder is further reduced.

[0077] [FIG. 32]

[0078]FIG. 32 is a figure showing the examples of the effective surface of action and the action limit curve of the hypoid gear, which corresponds to FIG. 29 and shows a surface of action in a case where the base cylinder is further reduced.

[0079] [FIG. 33]

[0080]FIG. 33 is a figure showing the examples of the effective surface of action and the action limit curve of the hypoid gear, which corresponds to FIG. 30 and shows a surface of action in a case where the base cylinder is further reduced.

[0081] [FIG. 34]

[0082]FIG. 34 is a figure showing a relationship of a point of contact P_(wsCC) of a tooth surface C_(c) at a rotation angle θ₁(=0) to the design reference point P₀.

[0083] [FIG. 35]

[0084]FIG. 35 is a figure showing an effective surface of action drawn by a pinion tooth surface D.

[0085] [FIG. 36]

[0086]FIG. 36 is a figure showing a gear conjugate tooth surface D generated by the pinion tooth surface D shown in FIG. 35.

[0087] [FIG. 37]

[0088]FIG. 37 is a figure showing an effective surface of action drawn by the pinion tooth surface C_(c).

[0089] [FIG. 38]

[0090]FIG. 38 is a figure showing a gear conjugate tooth surface C_(c) generated by the pinion tooth surface C_(c) shown in FIG. 37.

[0091] [FIG. 39]

[0092]FIG. 39 is a figure showing a line of intersection of the conjugate gear tooth surfaces D, C_(c) and planes of rotation of gear (Z_(2h)=0, 3, 6).

[0093] [FIG. 40]

[0094]FIG. 40 is a schematic block diagram of a system for supporting gear designing.

[0095] [FIG. 41]

[0096]FIG. 41 is a flowchart showing of the gear designing process.

BEST MODE FOR CARRYING OUT THE INVENTION

[0097] Hereinafter, embodiments of the present invention are described in accordance with the attached drawings. First, the gear design method disclosed in Japanese Patent Laid-Open Publication No. Hei 9-53702 is described.

[0098] A. New Tooth Profile Theory

[0099] 1. Tooth Profile in the New Tooth Profile Theory

[0100]FIG. 1 shows a state of tooth surfaces I, II contacting each other at point P_(l). The tooth surfaces I, II rotate at angular velocities ω_(1i), ω_(2i) (being vectors having normal directions shown in the figure), respectively, and respectively transmit certain input and output torque T₁, T₂ (having normal vectors in the same directions as those of the angular velocities ω₁ and ω_(2i), respectively) at a certain instance. In the aforesaid contact state, the tooth surface II receives a normal force F_(N2i) of a concentrated load, and the tooth surface I receives a normal force F_(N1i) (=−F_(N2i)) as the reaction of the normal force F_(N2i). If a common normal of the tooth surfaces I, II at the point of contact P_(i) is expressed by a unit vector n_(i), the n_(i), on the other hand, indicates a line of action (directed) of the normal force of the concentrated load.

[0101] If it is supposed that, when a pair of gears has rotated to a certain angular extent, the point of contact has moved to P_(j) and the angular velocities have changed to ω_(1j), ω_(2j), and further the normal forces of the concentrated load have changed to F_(N1j), F_(N2j), P_(i)P_(j) draws a path of contact such that common normals are n_(i), n_(j), respectively, at each point of contact. If the path of contact P_(l)P_(j) and the common normals n_(i), n_(j) are transformed into a space rotating with each gear, the path of contact P_(i)P_(j) is defined as a space curve on which the tooth profiles I, II transmit quite the same motion as those of the tooth surfaces I, II, and the path of contact P_(i)P_(j) expresses a path of movement (tooth bearing) of the concentrated load on the tooth surface. The tooth profiles I, II are tooth profiles in the new tooth profile theory, and the tooth profiles I, II are space curves having a normal (or a microplane) at each point.

[0102] Consequently, when considering a contact state of the tooth surfaces I, II nearby a point of contact and mechanical motions of the pair of gears, it is sufficient to consider the tooth profiles I, II in place of the tooth surfaces I, II. Furthermore, if the toothprofiles I, II are given, the tooth surfaces I, II transmitting quite the same mechanical motions may be a pair of curved surfaces including the tooth profiles I, II and not interfering with each other, with the pair of tooth surfaces being conjugate to each other being only one possible configuration.

[0103] As used herein, the concentrated load and its point of action refer to a resultant force of a distributed load (forming an osculating ellipse) of an arbitrary pair of tooth surfaces and its point of action. Consequently, the point of contact is the point of action of the concentrated load on the other hand, and the point of contact includes a deflection according to the concentrated load. Furthermore, because each of the pair of tooth surfaces is the same curved surface having one pitch of a phase difference from each other, the pair of tooth surfaces draws the same path of contact (including a deflection) in a static space according to its loaded state. In a case wherein a plurality of tooth surfaces are engaged with each other, concentrated loads borne by an adjoining pair of tooth surfaces at arbitrary rotation angles are in a row on the path of contact in the state of their phases being shifted from each other by pitches.

[0104] 2. Basic Coordinate System

[0105] For an arbitrary point P on a path of contact P_(l)P_(j), FIG. 2 shows the point P, normal forces F_(N2), F_(N1) of the concentrated loads at the point P, and a common normal n (a line of action of the concentrated load) at the point P by means of coordinate systems C₁, C₂ and coordinate systems C_(q1), C_(q2).

[0106] A shaft angle Σ, an offset E (≧0, a distance between a point C₁ and a point C₂), and the directions of angular velocities ω₁, ω₂ of two axes I, II are given. It is supposed that, when a common perpendicular of the two axes I, II is made to have a direction in which the direction of ω₂×ω₁, is positive to be a directed common perpendicular v_(c), the intersection points of the two axes I, II and the common perpendicular v_(c) are designated by C₁, C₂ and a situation wherein the C₂ is on the C₁ with respect to the v_(c) axis will be considered in the following. A case wherein the C₂ is under the C₁ would be very similar.

[0107] Planes including the normal force F_(N2) (common normal n) of the concentrated load and parallel to each of the gear axes I, II are defined as planes of action G₁, G₂. Consequently, the F_(N2) (common normal n) exists on the line of intersection of the planes of action G₁, G₂. Cylinders being tangent to the planes of action G₁, G₂ and having axes being the axis of each gear are defined as base cylinders, and their radii are designated by reference marks R_(b1), R_(b2).

[0108] The coordinate systems C₂, C_(q2) of a gear II are defined as follows. The origin of the coordinate system C₂ (u_(2c), v_(2c), z_(2c)) is set at C₂, its a_(2c) axis is set to extend into the ω₂ direction on a II axis, its V_(2c) axis is set as the common perpendicular v_(c) in the same direction as that of the common perpendicular v_(c), and its u_(2c) axis is set to be perpendicular to both the axes to form a right-handed coordinate system. The coordinate system C_(q2) (q₂, v_(q2), z_(2c)) has the origin C₂ and the z_(2c) axis in common, and is a coordinate system formed by the rotation of the coordinate system C₂ around the z_(2c) axis as a rotation axis by χ₂ (the direction shown in the figure is positive) such that the plane v_(2c) (=0) is parallel to the plane of action G₂. Its u_(2c) axis becomes a q_(2c) axis, and its v_(2c) axis becomes a v_(q2c) axis.

[0109] The plane of action G₂ is expressed by v_(q2c)=−R_(b2) by means of the coordinate system C_(q2). To the coordinate system C₂, the inclination angle of the plane of action G₂ to the plane v_(2c) (=0) is the angle χ₂, and the plane of action G₂ is a plane tangent to the base cylinder (radius R_(b2)).

[0110] The relationships between the coordinate systems C₂ and C_(q2) become as follows because the z_(2c) axis is in common.

u _(2c) =q _(2c) cos χ₂ −v _(q2c) sin χ₂

v _(2c) =q _(2c) sin χ₂ +v _(q2c)cos χ₂

[0111] Because the plane of action G₂ meets v_(q2c)=−R_(b2), the following expressions (1), are concluded if the plane of action G₂ is expressed by the radius R_(b2) of the base cylinder.

u _(2c) =q _(2c) cos χ₂ +R _(b2) sin χ₂

v _(2c) =q _(2c) sin χ₂ −R _(b2)cos χ₂

z _(2c) =z _(2c)  (1)

[0112] If the common normal n is defined to be on the plane of action G₂ and also defined such that the common normal n is directed in the direction in which the q_(2c) axis component is positive, an inclination angle of the common normal n from the q_(2c) axis can be expressed by ω_(b2) (the direction shown in the figure is positive). Accordingly, the inclination angle of the common normal n in the coordinate system C₂ is defined to be expressed by the form of n_(2c) (φ₂, ψ_(b2)) by means of the inclination angles φ₂ (the complementary angle of the χ₂) of the plane of action G₂ to the directed common perpendicular v_(c), and the ψ_(b2)

[0113] Here, the positive direction of the normal force F_(N2) of the concentrated load is the direction of then and the q₂ axis direction component, and the Z_(2c) axis direction component of the F_(N2) are designated by F_(q2), F_(z2), respectively.

[0114] As for the gear I, coordinate systems C₁ (u_(1c), v_(1c), z_(1c)), C_(q1) (q_(1c), v_(q1c), z_(1c)), a plane of action G₁, a radius R_(b1) of the base cylinder, and the inclination angle n_(1c) (φ₁, ψ_(b1)) of the common normal n can be similarly defined. Because the systems share a common z_(1c) axis, the relationship between the coordinate systems C₁ and C_(q1) can also be expressed by the following expressions (2).

u _(1c) =q _(1c) cos χ₁ +R _(b1) sin χ₁

v _(1c) =q _(1c) sin χ₁ −R _(b1) cos χ₁

z _(1c) =z _(1c)  (2)

[0115] The relationship between the coordinate systems C₁ and C₂ is expressed by the following expressions (3).

u _(1c) =−u _(2c) cos Σ−z _(2c) sin Σ

v _(1c) =v _(2c) +E

z _(1c) =u _(2c) sin Σ−z _(2c) cos Σ  (3)

[0116] The coordinate systems C₁ and C₂, and the coordinate systems C_(q1) and C_(q2), all defined above, are the basic coordinate systems of the new tooth profile theory proposed newly by the inventor of the present invention. The basic coordinate systems make it possible that the application scope of the present invention can be considered to include a hypoid gear and a bevel gear as well as cylindrical gears.

[0117] The relationship between inclination angles n(φ₁, φ_(b1)) and n (φ₂, φ_(b2)) of the common normal n can be obtained as follows because the n exists on the line of intersection of the planes of actions G₁, G₂. Each axis direction component of the coordinate system C₂ of the n can be expressed as follows.

L_(u2c)= cos ψ_(b2) sin φ₂(L _(u2c):the u _(2c) axis direction component of the n)

L _(v2c)= cos ψ_(b2) cos φ₂(L _(v2c):the v _(2c) axis direction component of the n)

L _(z2c)=sin ψ_(b2) (L _(z2c):the z _(2c) axis direction component of the n)

[0118] Incidentally, the absolute value of the common normal n is 1.

[0119] If each axis direction component of the coordinate system C₁ is expressed by each axis direction component of the coordinate system C₂, it can be expressed as follows by means of the expressions (3).

L _(u1c) =−L _(u2c) cos Σ−L _(z2c) sin Σ(L _(u1c):the u_(1c) axis direction component of the n)

L _(v1c) =L _(v2c) (L _(v1c):the v _(1c) axis direction component of the n)

L _(z1c) =L _(u2c) sin Σ−L _(z2c) cos Σ(L _(z1c):the z _(1c) axis direction component of the n)

[0120] Consequently, the following expressions (4) and (5), can be obtained. $\begin{matrix} \begin{matrix} {{\tan \quad \phi_{1}} = \quad {L_{u1c}/L_{v1c}}} \\ {= \quad {{{- \tan}\quad \phi_{2}\cos \quad \Sigma} - {\tan \quad \psi_{b2}\sin \quad {\Sigma/\cos}\quad \phi_{2}}}} \end{matrix} & (4) \\ \begin{matrix} {{\sin \quad \psi_{b1}} = \quad L_{z1c}} \\ {= \quad {{\cos \quad \psi_{b2}\sin \quad \phi_{2}\sin \quad \Sigma} - {\sin \quad \psi_{b2}\cos \quad \Sigma}}} \end{matrix} & (5) \end{matrix}$

[0121] Whereupon, the following expressions can be obtained.

φ₁ =n/2−χ₁

φ₂ =n/2−χ₂

[0122] 3. Path of Contact and its Common Normal

[0123]FIG. 3 shows the relationships among the point P on a path of contact, the common normal n, and a tangential plane W (shown by a line of intersection w with the plane of action G₂), and a point of contact P_(d), a common normal n_(d), and a tangential plane W_(d) after the rotation of the former set by a minute angle Δθ₂ in the coordinate systems C₂ and C_(q2). Here, the inclination angles of an arbitrary point of contact P and the common normal n at the point of contact P are expressed as follows by the coordinate system C₂ using the rotation angle θ₂ of the gear II as a parameter.

P{u _(2c)(θ₂),v _(2c)(θ₂),z _(2c)(θ₂)},

n{φ₂(θ₂),ψ_(b2)(θ₂)}

[0124] The positive direction of the rotation angle θ₂ is the direction shown in the figure. The, the following expression is realized.

φ₂(θ₂)=n/2−χ₂(θ₂)

[0125] When the point P is expressed by means of the aforesaid expressions (1) by the use of the coordinate system C_(q2), the point P can be expressed as follows.

P{q _(2c)(θ₂),−R _(b2)(θ₂),z _(2c)(θ₂) }

[0126] Furthermore, if the inclination angle on the plane of action G₂ of a tangential line of a path of contact is designated by n_(b2) (θ₂), the following expression (6) holds true.

(dz _(2c) /dθ ₂)/(dq _(2c) /dθ ₂)=tan η_(b2)(θ₂)  (6)

[0127] If it is supposed that the gear II has rotated by the small angle Δθ₂, the point of contact P has changed to P_(d), and the common normal n has changed to the n_(d), P_(d) and n_(d) can be expressed as follows.

P _(d) {q _(2c)(θ₂)+Δq _(2c) , −R _(b2)(θ₂)+ΔR _(b2) ,z _(2c)(θ₂)+Δz _(2c)}

n _(d){π/2−χ₂(θ₂)−Δχ₂, ψ_(b2)(θ₂)+AΔψ_(b2)}

[0128] It is supposed that a plane of action passing through the point P_(d) is designated by G_(2d), and that, when the gear II has been rotated by Δχ₂ such that the G_(2d) has become parallel to the plane of action G₂, the plane of action G_(2d) has moved to G_(2de) and the point P_(d) has moved to P_(de). Moreover, the orthogonal projection of the point P_(de) to the plane of action G₂ is designated by P_(df). The line of intersection of the plane of action G_(2d) and the tangential plane W_(d) at the point P_(d) is designated by w_(d), and the w_(d) is expressed by w_(d)′ passing at the point P_(df) by being projected on the plane of action G₂ as a result of the aforesaid movement. Furthermore, n_(d) is designated by n_(d)′. The intersection point of the w_(d)′ and a plane of rotation passing at the point P is designated by P_(dg). The w_(d)′ is located at a position where the w_(d)′ has rotated to the w by Δθ₂−Δχ₂ on the plane of action G₂ as a result of the rotation by Δƒ₂. Furthermore, the w_(d)′ inclines to the w by Δψ_(b2) at the point P_(df). Consequently, the amount of movement PP_(dg) of the w_(d)′ to the w in the q_(2c) axis direction can be expressed as follows. $\begin{matrix} {{PP}_{dg} = \quad {{\left\{ {{R_{b2}\left( \theta_{2} \right)} - {\Delta \quad {R_{b2}/2}}} \right\} \left( {{\Delta \quad \theta_{2}} - {\Delta \quad \chi_{2}}} \right)} +}} \\ {\quad {\Delta \quad z_{2c}\Delta \quad {\psi_{b2}/\cos^{2}}\quad {\psi_{b2}\left( \theta_{2} \right)}}} \\ {= \quad {{R_{b2}\left( \theta_{2} \right)}\left( {{\Delta \quad \theta_{2}} - {\Delta \quad \chi_{2}}} \right)}} \end{matrix}$

[0129] Consequently, a minute displacement Δz_(2c) on the plane of action G₂ caused by the minute angle Δθ₂ becomes as follows.

Δz _(2c)[tan {ψ_(b2)(θ₂)+Δψ_(b2)}+1/tan {η_(b2)(θ₂)+Δθ_(b2) }]=R _(b2)(θ₂)(Δθ₂−Δχ₂)

[0130] By the omission of second order minute amounts, the expression can be expressed as follows.

Δz _(2c) =R _(b2)(θ₂)(Δθ₂−Δχ₂)/{tan ψ_(b2)(θ₂)+1/tan θ_(b2)(θ₂) }

[0131] By the use of the aforesaid expression (6), Δq_(2c) can be expressed as follows.

Δq _(2c) =R _(b2)(θ₂)(Δθ₂−Δχ₂)/{tan ψ_(b2)(θ₂) tan θ_(b2)(θ₂)+1}

[0132] Because ΔR_(b2), Δχ₂, Δψ_(b2) and Δθ_(b2) are functions of θ₂, they can be expressed by the use of Δθ₂ formally as follows.

ΔR _(b2)=(dR _(b2) /dθ ₂)Δθ₂

Δθ_(b2)=(dη _(b2) /dθ ₂)Δθ₂

Δχ₂=(dχ ₂ /dθ ₂)Δθ₂

Δψ_(b2)(dψ _(b2) /dθ ₂)Δθ₂

[0133] By integration of the above expressions from 0 to θ₂, the following expressions (7) can be obtained. $\begin{matrix} \begin{matrix} {{q_{2c}\left( \theta_{2} \right)} = \quad {\int\left( {{R_{b2}\left( \theta_{2} \right)}{\left( {1 - {{\chi_{2}}/{\theta_{2}}}} \right)/\left\{ {{\tan \quad {\psi_{b2}\left( \theta_{2} \right)}\tan \quad {\eta_{b2}\left( \theta_{2} \right)}} + 1} \right\}}} \right)}} \\ {\quad {{\theta_{2}} + {q_{2c}(0)}}} \\ {{R_{b2}\left( \theta_{2} \right)} = \quad {{\int{\left( {{R_{b2}}/{\theta_{2}}} \right){\theta_{2}}}} + {R_{b2}(0)}}} \\ {{z_{2c}\left( \theta_{2} \right)} = \quad {\int\left\lbrack {{R_{b2}\left( \theta_{2} \right)}{\left( {1 - {{\chi_{2}}/{\theta_{2}}}} \right)/\left\{ {{\tan \quad {\psi_{b2}\left( \theta_{2} \right)}} + {{1/\tan}\quad {\eta_{b2}\left( \theta_{2} \right)}}} \right\}}} \right\rbrack}} \\ {\quad {{\theta_{2}} + {z_{2c}(0)}}} \\ {{\eta_{b2}\left( \theta_{2} \right)} = \quad {{\int{\left( {{\eta_{b2}}/{\theta_{2}}} \right){\theta_{2}}}} + {\eta_{b2}(0)}}} \\ {{\chi_{2}\left( \theta_{2} \right)} = \quad {{{\int{\left( {{\chi_{2}}/{\theta_{2}}} \right){\theta_{2}}}} + {\chi_{2}(0)}} = {{\Pi/2} - {\phi_{2}\left( \theta_{2} \right)}}}} \\ {{\psi_{b2}\left( \theta_{2} \right)} = \quad {{\int{\left( {{\psi_{b2}}/{\theta_{2}}} \right){\theta_{2}}}} + {\psi_{b2}(0)}}} \end{matrix} & (7) \end{matrix}$

[0134] The constants of integration indicate the coordinates of the point of contact P₀ at the time of the θ₂=0, the inclination angle of the common normal n₀ at the point of contact P₀, and the inclination angle of the tangential line of a path of contact on a plane of action. The expressions (7) are equations that express a path of contact and the common normal thereof by the coordinate system C_(q2) and uses the θ₂ as a parameter. For the determination of the expressions (7), it is sufficient that the specifications at a design reference point P₀ (θ₂=0), i.e. the following ten variables in total, can be given.

P ₀ {q _(2c)(0), −R _(b2)(0),z _(2c)(0)}

η_(b2)(0)

n ₀{π/2−χ₂(0),ψ_(b2)(0)}

dR _(b2) /dθ ₂

dη _(b2) /dθ ₂

dχ ₂ /dθ ₂

dψ _(b2) /dθ ₂

[0135] The expressions (7) are basic expressions of the new tooth profile theory for describing a tooth profile. Furthermore, the expressions (7) are a first function of the present invention.

[0136] If the point P is transformed to the coordinate system C₂ (u_(2c), v_(2c), z_(2c)), because z_(2c) is common, the following expressions (8) can be obtained from expressions (1).

u _(2c)(θ₂)=q _(2c)(θ₂) cos χ₂(θ₂)+R _(b2)(θ₂)sin χ₂(θ₂)

v _(2c)(θ₂)=q _(2c),(θ₂)sin χ₂(θ₂)−R _(b2)(θ₂)cos χ₂(θ₂)

z _(2c)(θ₂)=z _(2c)(θ₂)  (8)

[0137] The expressions (8) are a second function of the present invention. By the use of the aforesaid expressions (2), (3), (4), and (5), the point of contact P and the inclination angle of the common normal n at the point of contact P can be expressed by the following expressions (9), by means of the coordinate systems C, and C_(q1) by the use of the θ₂ as a parameter.

P{u _(1c)(θ₂),v _(1c)(θ₂),z _(1c)(θ₂) }

n {φ ₁(θ₂),ψ_(b1)(θ₂)}

P{q _(1c)(θ₂), −R _(b1)(θ₂),z _(1c)(θ₂)}  (9)

[0138] 4. Requirement for Contact and Rotation Angle θ₁ of Gear I

[0139] Because the common normal n of the point of contact P exists on the line of intersection of the planes G₁ and G₂, the requirements for contact can be expressed by the following expression (10).

R _(b1)(θ₂)(dθ ₁ /dt)cos ψ_(b1)(θ₂)=R _(b2)(θ₂)(dθ ₂ /dt)cos ψ_(b2)(θ₂)  (10)

[0140] Consequently, the ratio of angular velocity i(θ₂) and the rotation angle θ₁ of the gear I can be expressed by the following expressions (11). $\begin{matrix} \begin{matrix} {{i\left( \theta_{2} \right)} = \quad {\left( {{\theta_{1}}/{t}} \right)/\left( {{\theta_{2}}/{t}} \right)}} \\ {= \quad {{R_{b2}\left( \theta_{2} \right)}\cos \quad {{\psi_{b2}\left( \theta_{2} \right)}/\left\{ {{R_{b1}\left( \theta_{2} \right)}\cos \quad {\psi_{b1}\left( \theta_{2} \right)}} \right\}}}} \\ {\theta_{1} = \quad {\int{{i\left( \theta_{2} \right)}{\theta_{2}}\quad {\text{(integrated~~from~~0~~to~~}\theta_{2}\text{)}}}}} \end{matrix} & (11) \end{matrix}$

[0141] It should be noted that it is assumed that θ₁=0 when θ₂=0.

[0142] 5. Equations of Tooth Profile

[0143] 5.1 Equations of Tooth Profile II

[0144]FIG. 4 shows point P in a coordinate system C_(r2) (u_(r2c), v_(r2c), Z_(r2c)) rotating along with the gear II. The coordinate system C_(r2) has an origin C₂ and z_(2c) axis in common with the coordinate system C₂ and rotates around the z_(2c) axis by the θ₂. The u_(r2c) axis coincides with the r_(2c) axis when θ₂=0. Because a path of contact and the common normal thereof are given by the above expressions (7), the point P (u_(r2c), v_(r2c), z_(r2c)) and the normal n (φ_(r2), ψ_(b2)) at the point P, both being expressed in the coordinate system C_(r2), can be expressed by the following expressions (12).

χ_(r2)=χ₂(θ₂)−θ₂=π/2−φ₂(θ₂)−θ₂

φ_(r2)=φ₂(θ₂)+θ₂

u _(r2c) =q _(2c)(θ₂)cos χ_(r2) +R _(b2)(θ₂)sin χ_(r2)

v _(r2c) =q _(2c)(θ₂)sin χ_(r2) −R _(b2)(θ₂)cos χ_(r2)

z _(r2c) =z _(2c)(θ₂)  (12)

[0145] The expressions (12) is a third function of the present invention.

[0146] 5.2 Equations of Tooth Profile I

[0147] If a coordinate system C_(r1)(u_(r1c), v_(r1c), z_(r1c)) rotating by the θ₁ to the coordinate system C₁ is similarly defined, the point P (u_(r1c), v_(r1c), z_(r1c)) and the normal n (φ_(r1), ψ_(b1)) at the point P can be expressed by the following expressions (13), by means of the above expressions (9) and (11).

χ_(r1)=χ₁(θ₂)−θ₁=π/2−φ₁(θ₂)−θ₁

φ_(r1)=φ₁(θ₂)+θ₁

u _(r1c) =q _(1c)(θ₂)cos χ_(r1) +Rb ₁(θ₂)sin χ_(r1)

v_(r1c) =q _(1c)(θ₂)sin χ_(r1) −Rb ₁(θ₂)cos χ_(r1)

z _(r1c) =Z _(1c)(θ₂)  (13)

[0148] The coordinate system C_(r1) and the coordinate system C₁ coincide with each other when θ₁=0. The aforesaid expressions (12) and (13) generally express a tooth profile the ratio of angular velocity of which varies.

[0149] The three-dimensional tooth profile theory described above directly defines the basic specifications (paths of contacts) of a pair of gears in a static space determined by the two rotation axes and the angular velocities of the pair of gears without the medium of a pitch body of revolution (a pitch cylinder or a pitch cone). Consequently, according to the tooth profile theory, it becomes possible to solve the problems of tooth surfaces of all of the pairs of gears from cylindrical gears, the tooth surface of which is an involute helicoid or a curved surface approximate to the involute helicoid, to a hypoid gear, and the problems of the contact of the tooth surfaces using a common set of relatively simple expression through the use of unified concepts defined in the static space (such as a plane of action, a normal plane, a pressure angle, a helical angle and the like).

[0150] 6. Motion of a Pair of Gears and Bearing Loads

[0151] 6.1 Equations of Motion OF Gears II AND I AND Bearing Loads

[0152]FIG. 5 shows relationships among the normal force F_(N2) of the concentrated load of the gear II at the point of contact P shown in FIG. 2 and bearing loads B_(z2), B_(vq2f), B_(vq2r), B_(q2f), B_(q2r) by means of the coordinate system C_(q2). Here, it is assumed that the lubrication of the tooth surfaces is sufficient and the frictional force component of the concentrated load is negligible. Furthermore, it is also assumed that the gear II is rigidly supported by bearings b_(2a), b_(2f) and b_(2r) in both of its axis direction and its radius direction and the rigidity of the axis is sufficiently large. In the figure, “′” and “″” indicate the orthogonal projection of a point or a vector, respectively, to an object plane.

[0153] Because the gear II rotates around a fixed axle II by receiving the input (output) torque T₂ and the normal force F_(N2) of a concentrated load from the gear I, an expression of the equations of motion of the gear II and the bearing load is concluded to the following expressions (15), from the balances of torque and forces related to each axis of the coordinate system C_(q2)

J ₂(d ²θ₂ /dt ²)=F _(q2) R _(b2)(θ₂)+T ₂

B _(z2) =−F _(z2) =−F _(q2) tan ψ_(b2)(θ₂)

B _(vq2r) b ₂₀ =F _(z2) R _(b2)(θ₂)

B _(q2f) +B _(q2r) =−F _(q2)

B _(q2f) b ₂₀ =−F _(q2) {z _(2c)(θ₂)−z _(2cr) }+F _(q2) q _(2c)(θ₂)tan ψ_(b2)(θ₂)

B _(vq2f) +B _(vq2r)=0  (15)

[0154] where

[0155] J₂:moment of inertia of gear II

[0156] θ₂:rotation angle of gear II

[0157] T₂:input (output) torque of gear II (constant)

[0158] F_(q2), F_(z2):q_(2c) and z_(2c) axis direction components of normal force F_(2N)

[0159] B_(z2):z_(2c) axis direction load of bearing b_(2a)

[0160] B_(q2f, B) _(q2r):q_(2c) axis direction load of bearings b_(2f), b_(2r)

[0161] B_(vq2f), B_(vq2r):v_(q2c) axis direction load of bearings b_(2f), b_(2r)

[0162] z_(2cf), z_(2cr):z_(2c) coordinates of point of action of load of bearings b_(2f), b_(2r)

[0163] b₂₀:distance between bearings b_(2f) and b_(2r) (z_(2cf −z) _(2cr)>0).

[0164] It should be noted that the positive directions of load directions are respective axis directions of the coordinate system C_(q2). The situation of the gear I is the same.

[0165] 6.2 Equations of Motion of a Pair of Gears

[0166] By setting of the equations of motion of the gears I and II and the aforesaid the requirement for contact (10) to be simultaneous equations, the equations of motion of a pair of gears are found as the following expressions (16).

J ₁(d ²θ₁ /dt ²)=F _(q1) R _(b1)(θ₂)+T₁

J ₂(d ²θ₂ /dt ²)=F _(q2) R _(b2)(θ₂)+T₂

−F _(q1)/cos ψ_(b1)(θ₂)=F _(q2)/ cos ψ_(b2)(θ₂)

R _(b1)(θ₂)(dθ ₁ /d _(t))cos ψ_(b1)(θ₂)=R _(b2)(θ₂)(dθ ₂ /dt)cos ψ_(b2)(θ₂)  (16)

[0167] Because a point of contact and the common normal thereof are given by the aforesaid expressions (7), the aforesaid expressions (16) are simultaneous equations including unknown quantities θ₁, θ₂, F_(q1), F_(q2), and the expressions (16) are basic expressions for describing motions of a pair of gears the tooth profiles of which are given. Incidentally, the expressions (16) can only be applied to an area in which a path of contact is continuous and differentiable. Accordingly, if an area includes a point at which a path of contact is nondifferentiable (such as a point where a number of engaging teeth changes), it is necessary to obtain expressions for describing the motion in the vicinity of the point. It is not generally possible to describe a steady motion of a pair of gears only by the aforesaid expressions (16).

[0168] 7. Conditions for Making Fluctuations of Bearing Load Zero

[0169] Fluctuations of a load generated in the gear II because of the rotation of a pair of gears can be understood as fluctuations of the loads of the bearings b_(2a), b_(2f) and b_(2r) to the stationary coordinate system C₂. Accordingly, if each bearing load expressed in the coordinate system C_(q2) is transformed into an axis direction component in the coordinate system C₂, the result can be expressed by the following expressions (17).

B _(z2c) =B _(z2)(the Z₂C axis direction load of the bearing b_(2a))

B _(u2cf) =B _(q2f) cos χ₂ −B _(vq2f) sin χ₂(the u_(2c) axis direction load of the bearing b_(2f))

B_(Vv2cf) =B _(q2f) sin χ₂ +B _(vqf) cos χ₂ (the V_(2c) axis direction load of the bearing b_(2f))

B_(u2cr) =B _(q2r) cos χ₂ −B _(vq2r) sin χ₂ (the u_(2c) axis direction load of the bearing b_(2r))

B _(v2cr) =B _(q2r) sin χ₂ +B _(vq2r) cos χ₂(the V_(2c) axis direction load of the bearing b_(2r))  (17)

[0170] Fluctuation components of the bearing load can be expressed as follows by differentiation of the above expressions (17).

[0171] (a) Fluctuation Components of a_(2c) Axis Direction Load of Bearing b_(2a)

ΔB _(z2c) =ΔB _(z2) =−ΔF _(z2)

ΔF _(z2) =ΔF _(q2) tan ψ_(2b) +F _(q2) Δψb ₂/cos²ψ_(b2)

ΔF _(q2)={Δ(J ₂(d ²θ₂ /dt ²))−F _(q2) ΔR _(b2) }/R _(b2)

[0172] (b) Fluctuation Components of u_(2c) and v_(2c) Axis Direction Loads of Bearing b_(2f)

ΔB _(u2cf) =ΔB _(q2f) cos χ₂−B_(q2f) sin χ₂Δχ₂ −ΔB _(vq2f) sin χ₂ −B _(vq2f) cos χ₂Δχ₂

ΔB _(v2cf) =ΔB _(q2f) sin χ₂ +B _(q2f) cos χ₂Δχ₂ +ΔB _(vq2f) cos χ₂ −B _(vq2f) sin χ₂Δχ₂

ΔB _(q2f) =−[ΔF _(q2)(z _(2c) −z _(2cr) −q _(2c) tan ψ_(b2))+F _(q2) {Δz _(2c) −Δq _(2c) tan ψ_(b2) −q _(2c)Δψ_(b2)/cos²ψ_(b2) }]/b ₂₀

ΔB _(vq2f)=−(ΔF _(z2) R _(b2) +F _(z2) ΔR _(b2))/b ₂₀

[0173] (c) Fluctuation Components of u_(2c) and v_(2c) Axis Direction Loads of Bearing b_(2r)

ΔB _(u2cr) =ΔB _(q2r) cos χ₂ −B _(q2r) sin χ₂Δχ₂ −ΔB _(vq2r) sin χ₂ −B _(vq2r) cos χ₂Δχ₂

ΔB _(v2cr) =ΔB _(q2r) sin χ₂ +B _(q2r cos χ) ₂Δχ₂ +ΔB _(vq2r) cos χ2−B _(vq2r) sin χ₂Δχ₂

ΔB _(q2r) =−ΔF _(q2) −ΔB _(q2f)

ΔB _(vq2r) =−ΔB _(vq2f)

[0174] The fluctuation components of the bearing load of the gear II at an arbitrary rotation angle θ₂ can be expressed as fluctuation components of the following six variables.

[0175] Δq_(2c)

[0176] ΔR_(b2)

[0177] Δa_(2c)

[0178] Δχ₂

[0179] Δψ_(b2)

[0180] Δ(d²θ₂/dt²)

[0181] When the gear II rotates under the condition such that input (output) torque is constant, at least the fluctuation components of the bearing load of the gear II should be zero so that the fluctuations of the bearing load of the gear II may be zero- independent of rotation position. Consequently the following relationship holds true.

ΔB _(z2c) =ΔB _(u2cf) =ΔB _(v2cf) =ΔB _(u2cr) =ΔB _(v2cr)=0

[0182] Consequently, the conditions that the fluctuations of the bearing load of the gear II become zero are arranged to the following five expressions (18).

(1)Δχ₂=0

(2)Δψ_(b2)=0

(3)ΔR _(b2)(θ₂)=0

(4)Δz_(2c)(θ₂)=Δq _(2c)(θ₂) tan ψ_(b2)(θ₂)

(5)Δ(d ²θ₂ /dt ²)=0  (18)

[0183] In the above, t designates a time hereupon.

[0184] Each item of the aforesaid (1)-(5) is described in order.

[0185] (1) Condition of Δχ₂ (θ₂)=0

[0186] The inclination angle χ₂ (θ₂) of the plane of action G₂ is constant (designated by χ₂₀). That is, the angle χ₂ (θ₂) becomes as follows.

[0187] ti χ₂(θ₂)=χ₂(0)=χ₂₀=π/2−φ₂₀

[0188] (2) Condition of Δψ_(b2)(θ₂)=0

[0189] The inclination angle ψ_(b2) (θ₂) on the plane of action G₂ of the common normal of a point of contact is constant (ψ_(b20)). That is, the following expression is concluded.

ψ_(b2)(θ₂)=ψ_(b2)(0)=ψ_(b20)

[0190] (3) Condition of ΔR_(b2) (θ₂)=0

[0191] The base cylinder radius R_(b2)(θ₂) to which the common normal at a point of contact is tangent is constant (the constant value is designated by R_(b20)). That is, the following expression is obtained.

R _(b2)(θ₂)=R _(b2)(0)=R _(b20)

[0192] (4) Condition of Δz_(2c) (θ₂)=Δq_(2c)(θ₂)tan ψ_(b2)(θ₂)

[0193] From ψ_(b2) (θ₂)=ψ_(b20) and expressions (7), the following expressions are obtained.

Δz _(2c) =Δq _(2c)(θ₂)tan ψ₂₀

η_(b2)(θ₂)=ψ₂₂₀=η_(b2)(0)

[0194] That is, the inclination angle of a tangential line of a path of contact on the plane of action G₂ (q_(2c)c-z_(2c) plane) should coincide with that of the common normal.

[0195] If the results of the conditions (1)-(4) are substituted in the above expressions (7) in order to express the expressions (7) in the coordinate system C₂, a path of contact and the inclination angle of the common normal of the path of contact are expressed by the following expressions.

q _(2c)(θ₂)=R _(b20)θ₂ cos²ψ_(b20) +q _(2c)(0)

u _(2c)(θ₂)=q _(2c)(θ₂)cos χ₂₀ +R _(b20) sin χ₂₀

v _(2c)(θ₂)=q _(2c)(θ₂)sin χ₂₀ −R _(b20) cos χ₂₀

z _(2c)(θ₂)=R _(b20)θ₂ cos ψ_(b20) sin ψ_(b20) +z _(2c)(0)

n(φ₂₀=π/2−χ₂₀, ψ_(b20))  (19)

[0196] The expressions (19) indicate that the path of contact is a straight line passing at a point P₀{q_(2c)(0), −R_(b20), z_(2c) (0)} in the coordinate system C_(q2) and coinciding with the common normal of the inclination angle n(φ₂₀=π/2−χ₂₀, ψ_(b20)) to the coordinate system C₂. Furthermore, by specifying five variables of R_(b20), ψ_(b20), q_(2c) (0), χ₂₀ and z_(2c) (0), the expressions (19) can specify a path of contact.

[0197] If the expressions (19) are transformed into the coordinate systems C₁, C_(q1), the expressions (19) can be expressed as a straight line passing through the point P₀{q_(1c)(0), −R_(b10), z_(1c) (0)} and having an inclination angle n (φ₁₀=π/2−χ₁₀, ψ_(b10)) to the coordinate system C₁ by means of the above expressions (9). Consequently, the ratio of angular velocity and the rotation angle of the gear I can be expressed as follows by the use of the expressions (11).

i(θ₂)=(dθ ₁ /dt)/(dθ ₂ /dt)=R _(b20) cos ψ_(b20)/(R _(b10) cos ψ_(b10))=i₀θ₁ =i ₀θ₂  (20)

[0198] The ratio of angular velocity is constant (designated by i₀)

[0199] (5) Condition of Δ(d²θ₂/dt²)=0

[0200] (d²θ₂/dt²) is constant. That is, it describes motion of uniform acceleration. Because the motion of a pair of gears being an object in the present case is supposed to be a steady motion such that inputs and outputs are constant, the motion is expressed by (d²θ₂/dt²)=0, and the expression means a motion of uniform rate. Moreover, because (dθ₁/dt) also becomes constant by means of the aforesaid expressions (20), (d²θ₁/dt²)=0 is also concluded as to the gear I. Consequently, by means of the expressions (16), the following expressions can be obtained.

_(Fq2) R _(b20) =−T ₂

F _(q1) R _(b10) =−T ₁

[0201] By the use of the aforesaid expressions (20) and a law of action and reaction the following expression is concluded.

i ₀ =F _(q2) R _(b2)/(−F _(q1) R _(b10))=−T ₂ /T ₁

[0202] That is, the ratio of angular velocity i₀ of a pair of gears should be a given torque ratio (being constant owing to the supposition of the input and the output).

[0203] As for the fluctuations of a load to be produced in the gear I, a state wherein the fluctuation of a bearing load is zero is realized in accordance with the conditions of the aforesaid expressions (18) quite similarly to the gear II. Consequently, a path of contact and a common normal thereof should satisfy the following conditions in order to make fluctuations of a bearing load generated in a pair of gears zero under which input and output torques are constant.

[0204] (a) When a point of contact is arbitrarily given in a static space (in the coordinate system C₂), a path of contact should be a straight line coinciding with the common normal of the point of contact and being fixed in the static space.

[0205] (b) Furthermore, the ratio of angular velocity i₀ at the point of contact should be constant and coincide with a given torque ratio.

[0206]FIG. 6 shows relationships among a plane of action G₂₀ on which fluctuations of a bearing load are zero, a base cylinder (radius R_(b20)), a path of contact (common normal n) and the normal force F_(N2) of the concentrated load in the coordinate systems C₂ and C_(q2). If the path of contact is the same straight line in all of the surfaces of action (including a zone in which a plurality of contacts are included), the path of contact is continuous and differentiable in all of the zones. Consequently, a steady motion having no fluctuations of a bearing load can be realized.

[0207] 8. Tooth Profile Having no Fluctuations of Bearing Load

[0208] 8.1 Tooth Profile II

[0209] If a coordinate system having the origin C₂ and the a_(2c) axis in common with the coordinate system C₂ and rotating around the z_(2c) axis by the θ₂ is set to the coordinate system C_(r2)(u_(r2c), v_(r2c), z_(r2c)), a tooth profile II having no fluctuation of its bearing load can be obtained in accordance with the following expressions (21) by transforming the aforesaid expressions (19) into the coordinate system C_(r2).

χ_(r2)=χ₂₀−θ₂=π/2−φ₂₀−θ₂

u _(r2c) =q _(2c)(θ₂)cos χ_(r2) +R _(b20) sin χ_(r2)

v_(r2) =q _(2c)(θ₂)sin χ_(r2) −R _(b20 cos χ) _(r2)

z _(r2c) =z _(2c)(θ₂)

n(φ₂₀+θ₂, ψ_(b20))  (21)

[0210] Here, the u_(r2c) axis is supposed to coincide with the r_(2c) axis when the rotation angle θ₂ is zero.

[0211] 8.2 Tooth Profile I

[0212] Similarly, a coordinate system rotating around the Z_(1c) axis by the θ₁ is assumed to the coordinate system C_(r1) (u_(r1c), v_(r1c), z_(r1c)) to the coordinate system C₁. If the aforesaid expressions (19) is transformed into the coordinate systems C₁, C_(q1), the transformed expressions express a straight line passing at the point P₀ {q_(1c)(0), −R_(b10), z_(1c)(0)} and having the inclination angle n(φ₁₀=π/2−χ₁₀, ψ_(b10)) to the coordinate system C₁. Because an arbitrary point on the straight line is given by the aforesaid expressions (9), a tooth profile I having no fluctuations of bearing load can be obtained in accordance with the following expressions (22) by transforming the straight line into the coordinate system Cr1.

χ_(r1)=χ₁₀−θ₁=π/2−φ₁₀−θ₁

u_(r1c) =q _(1c)(θ₂)cos  _(r1) +R _(b10) sin χ_(r1)

v _(r1c) =q _(1c)(θ₂)sin χ_(r1) −R _(b10) cos χ_(r1)

z _(r1c) =Z _(1c)(θ₂)

n(φ₁₀+θ_(1, ψ) _(b10))  (22)

[0213] Here, a u_(r1c) axis is supposed to coincide with a u_(1c) axis when the rotation angle θ₁ is zero.

[0214] Now, if q_(1c) (θ₂) and z_(1C) (θ₂) are substituted by q_(1c)(θ₁) and Z_(1c) (θ₁) respectively, again by the use of θ₁=i₀θ₂ and the θ₁ as a parameter, the following expressions (23) can be obtained.

_(q1c)(θ₁)=R _(b10)θ_(1 cos) ²ψ_(b10) +q _(1c)(0)

z _(1c)(θ₁)=R _(b10)θ₀ cos ψ_(b10) sin ψ_(b10) +z _(1c)(0)

χ_(r1)=χ₁₀−θ₁=π/2−φ₁₀−θ₁

u _(r1c) =q _(1c)(θ₁)cos χ_(r1) +R _(b10) sin χ_(r1)

v _(r1c) =q _(1c)(θ₁)sin χ_(r1) −R _(b10) cos χ_(r1)

z _(r1c) =z _(1c)(θ₁)

n(φ₁₀+θ₁, ψ_(b10))  (23)

[0215] Practically the expressions (23) is easier to use than the expressions (22). The expressions (21), (23) show that the tooth profiles I, II are curves corresponding to the paths of contact on an involute helicoid. It is possible to use curved surfaces that include the tooth profiles I, II and do not interfere with each other as toothsurfaces. However, because the curved surfaces other than the involute helicoid or a tooth surface being an amended involute helicoid are difficult to realize the aforesaid path of contact and the common normal, those curved surfaces are not suitable for power transmission gearing.

[0216] A specific method for determining values to be substituted for the aforesaid five variables R_(b20), ψ_(b20), q_(2c)(0) χ₂₀, z_(2c)(0) for specifying the expressions (19) is described in detail.

[0217] 9. A Pair of Gears Being Objects

[0218] A pair of gears being objects having no fluctuation of a bearing load is defined as follows as described above.

[0219] (1) Positional relationships between two axes (a shaft angle Z, an offset E) and angular velocities ω₁₀, ω₂₀ (assumed to be ω₁₀≧ω₂₀) are given, and a motion of a constant ratio of angular velocity (i₀) is transmitted. Both angular velocities ω₁₀, ω₂₀ are vectors.

[0220] (2) A path of contact is given as a directed straight line g₀ coinciding with the common normal n at a point of contact and being fixed in a static space, and the planes of action of the pair of gears are designated by G₁₀, G₂₀. The g₀ is a unit vector indicating the direction of the path of contact and coincides with the n.

[0221] (3) The coordinate systems C₁, C_(q1), C₂, C_(q2) are given, and the path of contact g₀ is given as follows by the coordinate systems C₂, C_(q2), wherein, the g₀ can be expressed by the coordinate systems C₁, C_(q1) and the rotation angle θ₁ of the gear I by replacing the suffix 2 with 1.

q _(2c)(θ₂)=R _(b20)θ₂ cos²ψ_(b20) +q _(2c)(0)

u _(2c)(θ₂)=q _(2c)(θ₂)cos χ₂₀ +R _(b20) sin χ₂₀

[0222]v _(2c)(θ₂)=q _(2c)(θ₂)sin χ₂₀ −R _(b20) cos χ₂₀

z _(2c)(θ₂)=R _(b20)θ₂ cos ψ_(b20) sin ψ_(b20) +z _(hd 2c)(0)  (25)

[0223] where

[0224] θ₂:a rotation angle of the gear II;

[0225] q_(2c)(0), z_(2c)(0):q_(2c) and z_(2c) coordinates of the point of contact when the θ₂ is zero;

[0226] χ₂₀:the inclination angle of the plane of action G₂₀ of the gear II;

[0227] ψ_(b20):the inclination angle of the g₀ on the plane of action G₂₀; and

[0228] R_(b20):the radius of a base cylinder being tangent with the plane of action G₂₀.

[0229] Consequently, it is necessary to select five suitable constants of q_(2c),(0), Z_(2c)(0), R_(b20), χ₂₀, ψ_(b20) in order that the pair of gears being objects transmits the motion of given ratio of angular velocity i₀.

[0230] 10. Relative Rotation Axis and Coordinate System C_(s)

[0231] 10.1 Relative Rotation Axis

[0232]FIG. 7 shows a relationship between a relative rotation axis and a coordinate system C_(S). If a positional relationship between two axes I and II and their angular velocities ω₁₀, ω₂₀ are given, it is supposed that the intersection points of the common perpendicular v_(c) (the positive direction thereof is the direction of ω₂₀×ω₁₀) of the two axes with each of the axes I, II are designated by C₁, C₂, respectively, and the C₁ is located under the C₂ with respect to the v_(c). If a relative angular velocity ω_(r) (vector) is supposed to be ω_(r)=ω₁₀−ω₂₀ and the axis thereof is assumed to be a relative rotation axis S, and then if a plane including the relative rotation axis S and being perpendicular to the common perpendicular v_(c) is assumed to be a plane S_(H) and the intersection point of the plane S_(H) with the common perpendicular v_(c) is designated by the C_(S), the relative rotation axis S is a straight line passing at the C_(S), and the position of the relative rotation axis S can be determined as follows.

[0233] If the orthogonal projections of the two axes I (ω₁₀), II (ω₂₀) to the plane S_(H) are designated by I_(S) (ω₁₀″), IIs (ω₂₀″), respectively, and an angle of the I_(S) to the II_(S) when the plane S_(H) is viewed from the positive direction of the common perpendicular V_(c) to the negative direction thereof is designated by Ω, the I_(S) is in a zone of 0≦Ω≦n(the positive direction of the angle Ω is the counterclockwise direction) to the II_(S) in accordance with the definition of ω₂₀×ω₁₀. If an angle of the relative rotation axis S (ω_(r)) to the II_(S) on the plane S_(H) is designated by Ω_(S) (the positive direction of the angle Ω_(S) is the counterclockwise direction), the components of the ω₁₀ ″ and the ω₂₀″ that are orthogonal to the relative rotation axis on the plane S_(H) should be equal to each other in accordance with the definition of the relative rotation axis (ω_(r)=ω₁₀−ω₂₀). Consequently, the Ω_(S) satisfies the following expressions (26):

sin Ω_(S)/sin(Ω_(S)−Ω)=ω₁₀/ω₂₀; or

sin Γ_(S)/sin(Σ−Γ_(S))=ω₁₀/ω₂₀  (26).

[0234] wherein, Σ=π−Ω (shaft angle), Γ_(S)=π−Ω_(S). The positive directions are shown in the figure.

[0235] The position of the C_(S) on the common perpendicular v_(c) can be obtained as follows. FIG. 8 shows a relative velocity V_(s) (vector) of the point C_(s). In accordance with the aforesaid supposition, the C₁ is located under the position of the C₂ with respect to the common perpendicular v_(c) and ω₁₀≧ω₂₀. Consequently, the C_(S) is located under the C₂. If the peripheral velocities of the gears I, II at the point C_(S) are designated by V_(s1), V_(s2) (both being vectors), respectively, because the relative velocity V_(s) (=V_(s1)−V_(s2)) exists on the relative rotation axis S in accordance with the definition of the peripheral velocity, the components of the V_(s1), V_(s2) (existing on the plane S_(H) ) orthogonal to the relative rotation axis should always be equal to each other. Consequently, the relative velocity V_(s) (=V_(s1)−V_(s2)) at the point C_(s) is like the shapes as shown in the same figure on the plane S_(H) according to the location (Γ_(S)) of the relative rotation axis S, and the distance C₂C_(s) between the C₂ and the C_(s) can be obtained by the following expression (27). That is,

C ₂ C _(s) =E tan Γ _(s)/{tan(Σ−Γ_(s))+tan Γ_(s)}  (27).

[0236] The expression is effective within a range of 0≦Γ_(S)≦π, and the location of the C_(s) changes together with the Γ_(s), and the location of the point C_(s) is located above the C₁ in case of 0≦Γ_(s)≦π/2, and the location of the point C_(s) is located under the C₁ in case of π/2≦Γ_(S)≦π.

[0237] 10.2 Definition of Coordinate System C.

[0238] Because the relative rotation axis S can be determined in a static space in accordance with the aforesaid expressions (26), (27), the coordinate system C_(S) is defined as shown in FIG. 7. The coordinate system C_(S)(u_(c), v_(c), z_(c)) is composed of C_(S) as its origin, the directed common perpendicular v_(c) as its v_(c) axis, the relative rotation axis S as its z_(c) axis (the positive direction thereof is the direction of ω_(r)), and its u_(c) axis taken to be perpendicular to both the axes as a right-handed coordinate system. Because it is supposed that a pair of gears being objects transmits a motion of a constant ratio of angular velocity, the coordinate system C_(S) becomes a coordinate system fixed in the static space. And the coordinate system C_(s) is a basic coordinate system in case of treating a pair of gears performing the transmission of the motion of constant ratio of angular velocity together with the previously defined coordinate systems C₁, C₂ and their derivative coordinate systems.

[0239] 10.3 Relationship Among Coordinate Systems C_(S), C₁, C₂

[0240] If the points C₁, C₂ are expressed to be C₁ (0, v_(cs1), 0), C₂ (0, v_(cs2), 0) by the use of the coordinate system C_(s), v_(cs1), v_(cs2) are expressed by the following expressions (29).

v _(cs2) =C _(S)C₂ =E tan Γ_(s)/{tan(Σ−Γ_(S))+tan Γ_(s)}

v _(cs1) =C _(S)C₁ =V _(cs2) −E=−E tan(Σ−Γ_(S))/{tan(τ−Γ_(S))+tan Γ_(s)}  (29)

[0241] If it is noted that C₂ is always located above C_(s) with respect to the v_(c) axis, the relationships among the coordinate system C_(s) and the coordinate systems C₁, C₂ can be expressed as the following expressions (30), (31) by means of v_(cs1), V_(cs2), Σ and Γ_(s).

u _(1c) =u _(c) cos(Σ−Γ_(s))+z _(c) sin(Σ−Γ_(S))

v _(1c) =v _(c) −v _(cs1)

z _(1c) =−u _(c) sin(Σ−Γ_(S))+z _(c) cos(Σ−Γ_(S))  (30)

u _(2c) =−u _(c) cos Γ_(S) +z _(c) sin Γ_(S)

v _(2c) =v _(c) −v _(cs2)

z _(2c) =−u _(c) sin Γ_(S) −z _(c) cos Γ_(S)  (31)

[0242] The relationships among the coordinate system C_(S) and the coordinate systems C₁, C₂ is schematically shown in FIG. 9.

[0243] 11. Definition of Path of Contact g₀ by Coordinate System C_(s)

[0244] 11.1 Relationship Between Relative Velocity and Path of Contact g₀

[0245]FIG. 18 shows a relationship between the given path of contact g₀ and a relative velocity V_(rs) (vector) at an arbitrary point P on the g₀. Incidentally, “′” and “″” in the figure indicate an orthogonal projection on the plane being an object of a point or a vector. If the position vector of the P from an arbitrary point on the relative rotation axis S is designated by r when a tooth surface contacts at the arbitrary point P on the path of contact g₀, the relative velocity V_(rs) at the point P can be expressed by the following expression (32).

V _(rs)=ω_(r) ×r+V _(s)  (32)

[0246] where

[0247] ω_(r)=ω₁₀−ω₂₀

[0248] ω_(r)=ω₂₀ sin Σ/sin(Σ−Γ_(S))=ω₁₀ sin Σ/sin Γ_(S)

[0249] V_(s)=ω₁₀×[C₁C_(S)]−ω₂₀×[C₂C_(S)]

[0250] V_(s)=ω₂₀ E sin Γ_(s)=ω₁₀ E sin(Σ−Γ_(S))

[0251] Here, [C₁C_(S)] indicates a vector having the C₁as its starting point and the C_(S) as its end point, and [C₂C_(S)] indicates a vector having the C₂ as its starting point and the C_(S) as its end point.

[0252] The relative velocity V_(rs) exists on a tangential plane of the surface of a cylinder having the relative rotation axis S as an axis, and an inclination angle ψ to the V_(S) on the tangential plane can be expressed by the following expression (33). cosψ=|V_(s)|/|V_(rs)|. . . (33)

[0253] Because the path of contact g₀ is also the common normal of a tooth surface at the point of contact, the g₀ is orthogonal to the relative velocity V_(rs) at the point P.

V _(rs) ·g ₀=0

[0254] Consequently, the g₀ is a directed straight line on a plane N perpendicular to V_(rs) at the point P. If the line of intersection of the plane N and the plane S_(H) is designated by H_(n), the H_(n) is normally a straight line intersecting with the relative rotation axis S, through and the g₀ necessarily passing through the H_(n) if an infinite intersection point is included. If the intersection point of the g₀ with the plane S_(H) is designated by P₀, then P₀ is located on the line of intersection H_(n), and the g₀ and P₀ become as follows according to the kinds of pairs of gears.

[0255] (1) In Case of Cylindrical Gears of Bevel Gears (Σ=0, π or E =0)

[0256] Because V_(S)=0, the V_(rs) simply means a peripheral velocity around the relative rotation axis S. Consequently, the plane N includes the S axis. Hence, H_(n) coincides with the S, and the path of contact g₀ always passes through the relative rotation axis S. That is, the point P0 is located on the relative rotation axis S. Consequently, as for these pairs of gears, the path of contact g₀ is an arbitrary directed straight line passing at the arbitrary point P₀ on the relative rotation axis.

[0257] (2) In Case of Gear Other Than Ones Described Above (Σ≢0, π or E≢0)

[0258] In the case of a hypoid gear, a crossed helical gear or a wormgear, if the point of contact P is selected at a certain position, the relative velocity V_(rs), the plane N and the straight line H_(n), all peculiar to the point P, are determined. The path of contact g₀ is a straight line passing at the arbitrary point P₀ on the H_(n), and does not pass at the relative rotation axis S normally. Because the point P is arbitrary, g₀ is also an arbitrary directed straight line passing at the point P₀ on a plane perpendicular to the relative velocity V_(rs0) at the intersection point P₀ with the plane S_(H). That is, the aforesaid expression (32) can be expressed as follows.

V _(rs) =V _(rs0)+ω_(r) ×[P ₀ P]g ₀

[0259] Here, [POP] indicates a vector having the P₀ as its starting point and the P as its end point. Consequently, if V_(rs0)·g₀=0, V_(rs)·g₀=0, and the arbitrary point P on the g₀ is a point of contact.

[0260] 11.2 Selection of Design Reference Point

[0261] Among pairs of gears having two axes with known positional relationship and the angular velocities, pairs of gears with an identical path contacts g₀ have an identical tooth profile corresponding to g₀, with the only difference between them being which part of the tooth profile is used effectively. Consequently, in a design of a pair of gears, it is important at which position in a static space determined by the two axes the path of contact g₀ is disposed. Further, because a design reference point is only a point for defining the path of contact g₀ in the static space, it does not cause any essential difference at which position on the path of contact g₀ the design reference point is selected. When an arbitrary path of contact g₀ is given, the g₀ necessarily intersects with a plane S_(H) with the case where the intersection point is located at an infinite point. Accordingly, even when the intersection point is set as a design reference point, generality is not lost. In the present embodiment, it is designed to give the arbitrary point P₀ on the plane S_(H) (on a relative rotation axis in case of cylindrical gears and a bevel gear) as the design reference point.

[0262]FIG. 11 shows the design reference point P₀ and the path of contact g₀ by the use of the coordinate system C_(S). When the design reference point expressed by means of the coordinate system C_(S) is designated by P₀(u_(c0), v_(c0), z_(c0)), each coordinate value can be expressed as follows.

u _(c0) =O _(S) P ₀

V _(c0)=0

z _(c0) =C _(S) O _(S)

[0263] For cylindrical gears and a bevel gear, u_(c0)=0. Furthermore, the point O_(s) is the intersection point of a plane S_(s), passing at the design reference point P₀ and being perpendicular to the relative rotation axis S. and the relative rotation axis S.

[0264] 11.3 Definition of Inclination Angle of Path of Contact g₀

[0265] The relative velocity V_(rs0) at the point P₀ is concluded as follows by the use of the aforesaid expression (32).

V _(rs0)=ω_(r) ×[u _(c0) ]+V _(s)

[0266] where, [u_(c0]) indicates a vector having the O_(S) as its starting point and the P₀ as its end point. If a plane (u_(c)=u_(c0)) being parallel to the relative rotation axis S and being perpendicular to the plane S_(H) at the point P₀ is designated by S_(p). the V_(rso) is located on the plane S_(p), and the inclination angle ψ₀ of the V_(rs0) from the plane S_(H) (V_(c)=0) can be expressed by the following expression (34) by the use of the aforesaid expression (33).

tan ψ₀=ω_(r) u _(c0) /V _(s) =u _(c0) sin Σ/{E sin(Σ−Γ_(S))sin Γ_(S)}  (34)

[0267] Incidentally, the ψ₀ is supposed to be positive when u_(c0)≧0, and the direction thereof is shown in FIG. 10.

[0268] If a plane passing at the point P₀ and being perpendicular to V_(rs0) is designated by S_(n), the plane S_(n) is a plane inclining to the plane S_(s) by the ω₀, and the path of contact g₀ is an arbitrary directed straight line passing at the point P₀ and located on the plane S_(n). Consequently, the inclination angle of the g₀ in the coordinate system C_(S) can be defined with the inclination angle ψ₀ of the plane S_(n) from the plane S_(s) (or the v_(c) axis) and the inclination angle φ_(n0) from the plane S_(p) on the plane S_(n), and the defined inclination angle is designated by g₀ (ψ₀, φ_(n0)). The positive direction of the φ_(n0) is the direction shown in FIG. 11.

[0269] 11.4. Definition of g₀ by Coordinate System C_(s)

[0270]FIG. 9 shows relationships among the coordinate system C_(s), the planes S_(H), S_(s), S_(p) and S_(n), P₀ and g₀ (ψ₀, φ_(n0)). The plane S_(H) defined here corresponds to a pitch plane in case of cylindrical gears and an axis plane in case of a bevel gear according to the conventional theory. The plane S_(s) is a transverse plane, and the plane S_(p) corresponds to the axis plane of the cylindrical gears and the pitch plane of the bevel gear. Furthermore, it can be considered that the plane S_(n) is a normal plane expanded to a general gear, and that the φ_(n0) and the ψ₀ also a normal pressure angle and a helical angle expanded to a general gear, respectively. By means of these planes, pressure angles and helical angles of ordinary pairs of gears can be expressed uniformly to static spaces as inclination angles to each plane of common normals (the g₀'s in this case) of points of contact. The planes S_(n), φ_(n0) defined here coincide with those of a bevel gear of the conventional theory, and differ for other gears because the conventional theory takes pitch planes of individual gears as standards, and then the standards change to a static space according to the kinds of gears. By the conventional theory, if a pitch body of revolution (a cylinder or a circular cone) is determined, it is sufficient to generate a mating surface by fixing an arbitrary curved surface to the pitch body of revolution as a tooth surface, and in the conventional theory conditions of the tooth surface (a path of contact and the normal thereof) are not limited except the limitations of manufacturing. Consequently, the conventional theory emphasizes the selection of P₀ (for discussions about pitch body of revolution), and there has been little discussion concerning design of go (i.e. a tooth surface realizing the g₀) beyond the existence of tooth surface. For making fluctuations of a bearing load zero in the design of a pair of gears, the design of the g₀ is more important than the selection of the P₀.

[0271] As for a pair of gears having the given shaft angle Σ thereof, the offset E thereof and the directions of angular velocities, the path of contact g₀ can generally be defined in the coordinate system C_(s) by means of five independent variables of the design reference point P₀ (u_(c0), v_(c0), z_(c0)) and the inclination angle g₀ (ψ₀, φ_(n0)). Because the ratio of angular velocity i₀ and v_(c0)=0 are given as conditions of designing in the present embodiment, there are three independent variables of the path of contact g₀. That is, the path of contact g₀ is determined in a static space by the selections of the independent variables of two of (the z_(c0)), the φ_(n0) and the ψ₀ in case of cylindrical gears because the z_(co) has no substantial meaning, three of the z_(co), the φ_(n0) and the ψ₀ in case of a bevel gear, or three of the z_(c0), the φ_(n0) and the ψ₀ (or the u_(c0)) in case of a hypoid gear, a worm gear or a crossed helical gear. When the point P₀ is given, the ψ₀ is determined at the same time and only the φ_(n0) is a freely selectable variable in case of the hypoid gear and the worm gear. However, in case of the cylindrical gears and the bevel gear, because P₀ is selected on a relative rotation axis, both of ψ₀ and φ_(n0) are freely selectable variables.

[0272] 12. Transformation of Path of Contact g₀ to Coordinate Systems O₂, O₁

[0273] 12.1 Definition of Coordinate Systems O₂, O_(q2), O₁, O_(q1)

[0274]FIG. 12 shows the path of contact g₀ in coordinate systems O₂, O_(q2), O₁, O_(q1). The coordinate systems O₂ (u₂ v₂, z₂) O_(q2) (q₂, v_(q2), z₂) are coordinate systems having an origin at the intersection point O₂ of a plane of rotation Z₂₀ of the axis of the gear II passing at the design reference point P₀ with the axis of the gear II, and the coordinate systems O₂ and O_(q2) are the coordinate systems C₂, C_(q2) displaced by C₂O₂ in the z_(2c) axis direction in parallel. The coordinate systems O₁(u₁, v₁, z₁), O_(cq1) (q₁, v_(q1), z₁) are similarly coordinate systems having an origin being an intersection point O₁ of a plane Z₁₀ lying immediately under the axis of the gear I passing at the point P₀ with the axis of the gear I, and the coordinate systems O₁ and O_(q1) are the coordinate systems C₁ and C_(q1) displaced by C₁O₁ in the Z_(1c) axis direction in parallel.

[0275] 12.2 Transformation Expression of Coordinates of Path of Contact

[0276] The relationships among the coordinate systems C₂ and O₂, C_(q2) and O_(q2), and O₂ and O_(q2) are as follows.

[0277] (1) Coordinate Systems C₂ and O₂

u ₂ =u _(2c)

v ₂ =v _(2c)

z ₂ =z _(2c) z _(2co)

[0278] where z_(2co)=C_(S)O_(2s)=−(u_(c0) sin Γ_(s)+z_(c0)cos Γ_(s))

[0279] (2) Coordinate Systems C_(q2) and O_(q2)

q ₂ =q _(2c)

v ₂ =v _(q2c)

z ₂ =z _(2c) −z _(2c0)

[0280] where z_(2c0)=C_(s)O_(2s)=−(u_(c0) sin Γ_(s)+z_(c0) cos Γ_(s)).

[0281] (3) Coordinate Systems O₂ and O_(q2) (Z₂ are in Common)

u ₂ =q ₂ cos χ₂ +R _(b2) sin χ₂

v ₂ =q ₂ sin χ₂ −R _(b2) cos χ₂

χ₂=π/2−φ₂

[0282] Quite similarly, the relationships among the coordinate systems C₁ and O₁, C_(q1) and O_(q1), and O₁ and O_(q1) are as follows.

[0283] (4) Coordinate Systems C₁ AND O₁

u ₁ =u _(1c)

v ₁ =v _(1c)

z ₁ =z _(1c) −z _(cc0)

[0284] where Z_(1Cc0)=C_(S)O_(1s)=−u_(c0) sin(Σ−Γ_(s))+z_(c0) cos(Σ−Γ_(s))

[0285] (5) Coordinate Systems C_(q1) and O_(q1)

q ₁ =q _(1c)

v _(q1) =v _(q1c)

z ₁ =z _(1c) −z _(1c0)

[0286] where z_(1c0)=C_(s01s)=−u_(c0) sin(Σ−Γ_(s))+z_(c0) cos(Σ−Γ_(s))

[0287] (6) Coordinate Systems O₁ AND O_(q1) (z₁ is in Common)

u ₁ =q ₁ cos χ₁ +R _(b1) sin χ₁

v ₁ =q ₁ sin χ₁ −R _(b1) cos χ₁

χ₁=π/2−φ_(1,)

[0288] (7) Relationships Between Coordinate Systems O₁ AND O₂

u ₁ =−u ₂ cos Σ−(z ₂ +z _(2c0))sin Σ

v ₁ =v ₂ +E

z ₁ =u ₂ sin Σ−(z ₂ +z _(2c0))cos Σ−z _(1c0)

[0289] 12.3 Transformation Expression of Inclination Angle of Path of Contact

[0290] If a plane including g₀ and parallel to the gear axis II is set as the plane of action G₂₀, the inclination angle of the g₀ on the coordinate system O₂ can be expressed as g₀(φ₂₀, ψ₂₀) by means of the inclination angle φ₂₀ (the complementary angle of the χ₂₀) from the v₂ axis of the plane of action G₂₀ and the inclination angle ψ_(b20) from the q₂ axis on the plane of action G₂₀. Quite similarly, the plane of action G₁₀ is defined, and the inclination angle of the g₀ can be expressed as g₀ (φ₁₀, ψ_(b10)) by means of the coordinate system O₁.

[0291]FIG. 13 shows relationships among g₀ (ψ₀, φ_(n0)), g₀(φ₁₀, ψ_(b10)) and g₀ (φ₂₀, ψ_(b20)). If it is assumed that a point of contact has moved from P₀ to P on the path of contact g₀ due to the rotation of the pair of gears and the displacement P₀P=L_(g) (positive when θ₂>0), each axis direction component of the coordinate system C_(s) can be expressed as follows.

L _(uc) =−L _(g) sin φ_(n0)(L _(uc):the u_(c) direction component of the L_(g))

L _(vc) =L _(g) cos φ_(n0) cos ψ₀(L _(vc):the v_(c) direction component of the L_(g))

L _(zc) =L _(g) cos φ_(n0) sin ψ₀(L _(zc):the z_(c) direction component of the L_(g))

[0292] Each axis direction component of the coordinate system O₂ can be expressed as follows by means of expressions (31) using each axis direction component of the coordinate system C_(S).

L _(u2) =−L _(uc 6)cos Γ_(s) +L _(zc) sin Γ_(S)(L _(u2):the u₂ direction component of the L_(g))

L _(v2) =L _(vc)(L _(v2):the v₂ direction component of the L_(g))

L _(z2) =−L _(uc) sin Γ_(s) −L _(zc) cos Γ_(s)(L _(z2):the z₂ direction component of the L_(g))

[0293] Consequently, the g₀(φ₂₀, ψ_(b20)) is concluded as follows.

tan φ₂₀ =L _(u2) /L _(v2)= tan φ_(n0) cos Γ_(s)/cos ψ₀+tan ψ₀ sin Γ_(s)  (35)

sin ψ_(b20) =L _(z2) /L _(g)=sin φ_(n0) sin Γ_(s)−cos φ_(n0) sin ψ₀ cos Γ_(s)  (36)

[0294] Quite similarly, the g₀ (φ₁₀, ψ_(b10)) is concluded as follows.

tan φ₁₀ =L _(u1) /L _(v1=−tan φ) _(n0) cos(Σ−rΓ_(s))/cos ψ₀+tan ψ₀ sin(Σ−Γ_(s))  (37)

sin ψ_(b10) =L _(z1) /L _(g)=sin φ_(n0) sin(Σ−Γ_(s))+cos φ_(n0) sin ψ₀ cos(Σ−Γ_(s))  (38)

[0295] From the expressions (35), (36), (37), and (38), relationships among the g₀(ψ₀, φ_(n0)), the g₀(φ₁₀, ψ_(b10)) and the g₀ (φ₂₀, ψ_(b20)) are determined. Because the above expressions are relatively difficult to use for variables other than φ_(n0) and ψ₀, relational expressions in the case where g₀(φ₁₀, ψ_(b10)) and g₀(φ₂₀, ψ_(b20)) are given are obtained here.

[0296] (1) Relational Expressions for Obtaining g₀(ψ₀, φ_(n0)) AND g₀(φ₁₀, ψ_(b10)) From g₀(φ₂₀, ψ_(b20))

sin φ_(n0)= cos ψ_(b20) sin φ₂₀ cos Γ_(s)+sin ψ_(b20) sin Γ_(s)  (39)

tan ψ₀= tan φ₂₀ sin Γ_(s)−tan ψ_(b20) cos Γ_(s)/cos φ₂₀  (40)

tan φ₁₀= tan φ₂₀ sin(Σ−π/2)−tan ψ_(b20) cos(Σ−π/2)/cos φ₂₀  (41)

sin ψ_(b10) = cos ψ_(b20) sin φ₂₀ cos(Σ−π/2)+sin ψ_(b20) sin(Σ−π/2)  (42)

[0297] (2) Relational Expressions for Obtaining g₀ (ψ₀, φ_(n0)) and g₀ (φ₂₀, ψ_(b20)) From g₀(φ₁₀, ψ_(b10))

sin φ_(n0)=−cos ψ_(b10) sin φ₁₀ cos(Σ−Γ_(s))+sin ψ_(b10) sin(Σ−Γ_(s))  (43)

tan ψ₀= tan  ₁₀ sin(Σ−Γ_(s))+tan ψ_(b10) cos(Σ−Γ_(s))/cos φ₁₀  (44)

tan φ₂₀= tan φ₁₀ sin(Σ−π/2)+tan ψ_(b10) cos(Σ−π/2)/cos φ₁₀  (45)

sin ψ_(b20)=−cos ψ_(b10) sin φ₁₀ cos(Σ−π/2)+sin ψ_(b10) sin(Σ−π/2)  (46)

[0298] 12.4 Path of Contact g₀ Expressed by Coordinate System O₂

[0299] Next, the equation of a path of contact by the coordinate system O₂ is described. FIG. 14 shows the path of contact g₀ and the corresponding tooth profile II. It is supposed that the path of contact g₀ contacts at the design reference point P₀ when θ₂=0, and that the tangential plane at that time is designated by W₀ (expressed by a line of intersection with the plane of action in the same figure). It is also supposed that the point of contact has moved to the P and the tangential plane has moved to the W after the gear II has rotated by the θ₂

[0300] (1) Design Reference Point P₀

[0301] A design reference point is given at P₀(u_(c0), 0, z_(c0)) by the coordinate system C_(s). Here, it is assumed that z_(c0)≧0 and u_(c0)=0 especially in case of cylindrical gears and a bevel gear. Consequently, if the design reference point expressed by the coordinate system O₂ is designated by P₀ (u_(2p0), −v_(cs2), 0), u_(2P0) can be expressed as follows by means of the expressions (31).

u_(2p0) =O _(2s) P ₀ =−u _(c0) cos Γ_(s) +z _(c0) sin Γ_(s)  (47)

[0302] Because the g₀ (φ₂₀, ψ_(b20)) is given by the aforesaid expressions (35) and (36), if the P₀ (u_(2p0), −v_(cs2), 0) is expressed by the P₀ (q_(2p0), −R_(b20), 0) by transforming the P₀ (u_(2p0), −v_(cs2), 0) into the coordinate system O_(q2), the q_(2p0) and the R_(b20) are as follows.

q _(2p0) =u _(2p0 cos χ) ₂₀ −v _(cs2) sin χ₂₀

R _(b20) =u _(2p0) sin χ₂₀ +v _(cs2) cos χ₂₀

χ₂₀=π/2−φ₂₀  (48)

[0303] (2) Equations of Path of Contact g₀

[0304] If the expressions (25) is transformed into the coordinate systems O₂ and O_(q2) and the expressions (48) are substituted for the transformed expressions (25), the equations of the path of contact g₀ are concluded as follows by the coordinate system O₂ as the coordinates of the point of contact P at the rotation angle θ₂. When θ₂=0, the path of contact g₀ contacts at the design reference point P₀.

q ₂(θ₂)=R _(b20)θ₂ cos²ψ_(b20) +q _(2p0)

u ₂(θ₂)=q ₂(θ₂)cos χ₂₀ +R _(b20) sin χ₂₀

v ₂(θ₂)=q ₂(θ₂)sin χ₂₀ −R _(b20) cos χ₂₀

z ₂(θ₂)=R _(b20)θ₂ cos ψ_(b20) sin ψ_(b20)  (49)

[0305] 12.5 Path of Contact g₀ Expressed by Coordinate System O₁

[0306]FIG. 15 shows the path of contact g₀ and the corresponding tooth profile I. Because g₀ (φ₁₀, ψ_(b10)) is given by the aforesaid expressions (37) and (38), if the design reference point P₀(u_(c0), 0, z_(c0)) is transformed into the coordinate systems O₁ and O_(q1) to be expressed by P₀ (u_(1po), −v_(cs1), 0) and p₀ (q_(1po), −R_(b10), 0) quite similarly to the case of coordinate system O₂, u_(1p0), q_(1p0) and R_(b10) are concluded as follows by means of the aforesaid expressions (30).

u _(1p0) =O _(1s) P ₀ =u _(c0) cos(Σ−Γ_(s))+z _(c0) sin(Σ−Γ_(s))

q _(1p0) =u _(1p0) cos χ₁₀ −v _(cs1) sin χ₁₀

R _(b10) =u _(1p) sin χ₁₀ +v _(cs1) cos χ10

χ₁₀=π/2−φ₁₀

[0307] Consequently, the equations of the path of contact g₀ are concluded as follows by expressing the aforesaid expressions (25) using the coordinate systems O1 and O_(q1) and θ₁.

θ₁ =i ₀ƒ₂(θ₁=0 when θ₂=0)

q ₁(θ₁)=R _(b10)θ₁ cos²ψ_(b10) +q _(1p0)

u ₁(θ₁)=q ₁(θ₁)cos χ₁₀ +R _(b10) sin χ₁₀

v ₁(θ₁)=q ₁(θ₁)sin χ₁₀ −R _(b10) cos χ₁₀

z ₁(θ₁)=R _(b10)θ₁ cos ψ_(b10) sin ψ_(b10)  (49-1)

[0308] Because the path of contact go is given as a straight line fixed in static space and the ratio of angular velocity is constant, the equations of the path of contact can be expressed in the same form independently from the positional relationship of the two axes.

[0309] 13. Equations of Tooth Profile

[0310] 13.1 Equations of Tooth Profile II

[0311]

[0312]FIG. 14 shows a tooth profile II using a coordinate system O_(r2) (u_(r2), V_(r2), z_(r2)) rotating at the θ₂ together with the gear II. The coordinate system O_(r2) has an origin O₂ and a z₂ axis in common with the coordinate system O₂, and coincide at the time of θ₂=0. Because the path of contact go is given by the expressions (49), the equations of the tooth profile II expressed by the rotary coordinate system O_(r2) are concluded as follows.

χ_(r2)=χ₂₀−θ₂=π/2−φ₂₀−θ₂

u _(r2) =q ₂(θ₂)cos χ_(r2) +R _(b20) sin χ_(r2)

v _(r2) =q ₂(θ₂)sin χ_(r2) −R _(b20) cos χ_(r2)

z _(r2) =R _(b20)θ₂ cos ψ_(b20) sin ψ_(b20)  (50)

[0313] 13.2 Equations of Tooth Profile I

[0314]FIG. 15 shows a tooth profile I in a coordinate system O_(r1) (u_(r1), v_(r1), z_(r1)) rotating at θ₁ together with the gear I and the coordinate system O₁. The origin O1 and the z₁ axis of coordinate system O_(r1) are in common with those of the coordinate system O₁, with which it corresponds at the time of θ₁=0. Because the path of contact g₀ is given by the expressions (49-1), equations of the toothprofile I expressed by the rotary coordinate system O_(r1) are concluded as follows.

χ_(r1)=χ₁₀−θ₁=π/2−φ₁₀ −θ₁

u _(r1) =q ₁(θ₁)cos χ_(r1) −R _(b10) sin χ_(r1)

v _(r1) =q ₁ ^((θ) ₁)sin χ_(r1) −R _(b10 cos χ) _(r1)

z _(r1) =R _(b10)θ₁ cos ψ_(b10) sin _(b10)  (53)

[0315] Next, a specific method for determining a tooth surface from a determined tooth profile is described in detail on the basis of the figures.

[0316] 14. Definition of a Pair OF Gears as Objects

[0317] It is supposed that an involute pair of gears being objects of the invention is defined as follows. If the tooth profiles corresponding to the path of contact g₀ are severally supposed to be the tooth profiles I, II, an involute helicoid including the tooth profile II is given as the tooth surface II, and a curved surface generated by the tooth surface II at the constant ratio of angular velocity i₀ is supposed to be the tooth surface I (consequently including the toothprofile I). If the tooth surfaces of the involute pair of gears defined in such a way are made to contact with each other along the toothprofiles I, II, fluctuations of a bearing load become zero. Consequently the involute pair of gears becomes the most advantageous pair of gears as a pair of gears for power transmission in view of the fluctuations of a load. Then, hereinafter, the relational expression of the involute pair of gears, i.e. equations of the involute helicoid, the surface of action thereof and the conjugate tooth surface I thereof, are described.

[0318] 15. Equations of Involute Helicoid (Tooth Surface II)

[0319] 15.1 Equations of Plane of Action G₂₀

[0320]FIG. 25 shows the plane of action G₂₀ (the inclination angle thereof:χ₂₀=π/2−φ₂₀) including the design reference point P₀ and the path of contact g₀, both being given by the aforesaid expressions (25) using the coordinate systems O_(2, O) _(q2). The line of intersection of the tangential plane W₀ and the G₂₀ at the point P₀ is shown as a straight line w₀. It is assumed that the point of contact P₀ has moved to the P and the w₀ has moved to the w when the gear II has rotated by θ₂.

[0321] Because the tooth surface normal n of an arbitrary point on the w is located on the plane of action G₂₀ and the inclination angle ψ_(b20) of the tooth surface normal n from the q₂ axis is constant in accordance with the definition of the involute helicoid, the tooth surface normal n is a straight line passing at the point P on the g₀ and perpendicular to g₀. Consequently, the involute helicoid can be defined to be a trajectory surface drawn by the line of intersection w, moving on the G₂₀ in the q₂ axis direction by R_(b20)θ₂ in parallel together with the rotation of the gear II (rotation angle is θ₂), in a rotating space (the coordinate system O_(r2)) fixed to the gear II. Then, if an arbitrary point on the straight line w is designated by Q and the point Q is expressed by the coordinate system O_(r2), the involute helicoid to be obtained can be expressed as a set of Q values.

[0322] If a directed straight line passing at the arbitrary point Q on the w and located on the plane of action G₂₀ perpendicular to w is designated by n (the positive direction thereof is the same as that of g₀) and the intersection point of n and w₀ is designated by Q₀, the point Q₀ (q₂₀, −R_(b20), z₂₀) expressed by the coordinate system O_(q2) can be determined as follows.

q ₂₀ =q _(20p0) −z ₂₀ tan ψ_(b20)

[0323] Consequently, if the point Q is expressed by the coordinate system O_(q2), the Q(q₂, −R_(b20), z₂) is expressed as follows.

q _(2 l (θ) ₂, z₂₀)=R _(b20)θ₂ cos² ψ_(b20) +q ₂₀ =R _(b20)θ₂ cos² ψ_(b20) +q _(2p0) −z ₂₀ tan ψ_(b20)

z ₂(θ₂, z₂₀)=R _(b20)θ₂ cos ψ_(b20) sin ψ_(b20) +z ₂₀

[0324] Moreover, if the point Q is expressed by the coordinate system O₂, the Q(u₂, n₂, z₂) is found as follows.

q ₂(θ₂, Z₂₀)=R _(b20)θ₂ cos² ψ_(b20) +q _(2p0) −z ₂₀ tan ψ_(b20)

u ₂(θ₂ ,z ₂₀)=q ₂(θ₂ ,z ₂₀)cos χ₂₀ +R _(b20) sin χ₂₀

v ₂(θ₂ ,z ₂₀)=q ₂(θ₂ ,z ₂₀)sin χ₂₀ −R _(b20) cos χ₂₀

z ₂(θ₂ ,z ₂₀)=R _(b20)θ₂ cos ψ_(b20) sin ψ_(b20) +z ₂₀  (54)

[0325] The expressions (54) is the equation of the plane of action G₂₀ that is expressed by the coordinate system O₂ by the use of the O₂ and the z₂₀ as parameters. If the O₂ is fixed, the line of intersection w of the tangential plane W and the plane of action G₂₀ is expressed, and if the z₂₀ is fixed, the directed straight line n on the plane of action is expressed. Because the path of contact g₀ is also a directed straight line n passing at the point P₀ the aforesaid expression (49) can be obtained by the setting of z₂₀=0.

[0326]15.2 Equations of Involute Helicoid

[0327] If the straight line w in FIG. 16 is transformed into a coordinate system rotating together with the gear II, the locus of the straight line w draws an involute helicoid (the base cylinder radius thereof:R_(b20), the helical angle thereof:ψ_(b20)). Accordingly, it is supposed that the locus of the straight line w is given as the tooth surface II. At this point, the directed straight line n at the point Q is the tooth surface normal n.

[0328]FIG. 17 shows an arbitrary point P_(m) on an involute helicoid (the tooth surface II) passing at the straight line w at the rotation angle θ₂ in the coordinate system O₂. If it is supposed that the w is at w_(m) when the tooth surface II has further rotated from the w by ξ₂, the intersection point Q_(m) of the w_(m) and the n can be expressed as follows.

q _(2m)(θ₂ ,z ₂₀,ξ₂)=q ₂(θ₂ ,z ₂₀)+R _(b20)ξ₂ cos²ψ_(b20)

z _(2m)(θ₂ ,z ₂₀,ξ₂)=z ₂(θ₂ ,z ₂₀)+R _(b20)ξ₂ cos ψ_(b20) sin ψ_(b20)

[0329] If a rotary coordinate system O_(r2m) is a coordinate system that coincides with the coordinate system O₂ when the rotation angle θ₂ and rotates by the ξ₂ around the z₂ axis, Q_(m)(u_(r2m), v_(r2m), z_(r2m)) can be expressed by the coordinate system O_(r2m) as follows.

χ_(r2m)=χ₂₀−ξ₂=π/2−φ₂₀−ξ₂

u _(r2m)(θ₂ ,z ₂₀,ξ₂)=q _(2m)(θ₂ ,z ₂₀,ξ₂)cos χ_(r2m) +R _(b20) sin χ_(r2m)

v _(r2m)(θ₂ ,z ₂₀,ξ₂)=q _(2m)(θ₂ ,z ₂₀,ξ2)sin χ_(r2m) R _(b20) cos χ_(r2m)

z _(r2m)(θ₂ ,z ₂₀,ξ₀)=z ₂(θ₂ ,z ₂₀)+R _(r20)ξ₂ cos ψ_(b20) sin ψ_(b20)

[0330] If the coordinate system O_(r2m) is rotated by the ξ₂ in the reverse direction of the θ₂ to be superposed on the coordinate system O₂, the Q_(m) moves to the P_(m). Because the point Q_(m) on the coordinate system O_(r2m) is the point P_(m) on the coordinate system O₂ and both of points have the same coordinate values, the P_(m)(u_(2m), v_(2m), z_(2m)) becomes as follows if the point P_(m) is expressed by the coordinate system O₂.

χ_(r2m)=χ₂₀−ξ₂=π/2−φ₂₀−ξ₂

q _(2m)(θ₂ ,z ₂₀,ξ₂)=q ₂(θ₂ ,z ₂₀)+R _(b20)ξ₂ cos² ψ_(b20)

u _(2m)(θ₂ ,z ₂₀,ξ₂)=q _(2m)(θ₂ ,z ₂₀,ξ₂)cos χ_(2m) +R _(b20) sin χ_(2m)

v _(2m)(θ₂ ,z ₂₀,ξ₂)=q _(2m)(θ₂ ,z ₂₀,ξ₂)sin χ_(2m) −R _(b20) cos χ_(2m)

z _(2m)(θ₂ ,z ₂₀,ξ₂)=z ₂(θ₂ ,z ₂₀)+R _(b20)ξ₂ cos ψ_(b20) sin ψ_(b20)  (55)

[0331] The expressions (55) are equations of the involute helicoid (the tooth surface II) passing at the point P on the path of contact g₀ at the arbitrary rotation angle θ₂ and using the z₂₀ and the ξ₂ as parameters by the coordinate system O₂. Supposing θ₂=0, the expressions (55) define the tooth surface II passing at the design reference point P₀. Moreover, supposing z₂₀=0, the expressions (55) become the expressions (50), i.e. the tooth profile II passing at the point P₀. Or, the expressions (55) can be considered as the equations of the point P_(m) on a plane G_(2m), being the point Q_(m) on the plane of action G₂₀ rotated by the ξ₂ into the reverse direction of the θ₂, by the coordinate system O₂. When the involute helicoid passing at the point P is examined on the coordinate system O₂, the latter interpretation simplifies analysis.

[0332] 16. Line of Contact and Surface of Action

[0333] When the tooth surface II is given by the expressions (55), the line of contact passing at the point P is a combination of the z₂₀ and the ξ₂, both satisfying the requirement for contact when the θ₂ is fixed. Consequently, the line of contact can be obtained as follows by the use of the ξ₂ as a parameter.

[0334] 16.1 Common Normal n_(m)(P_(m0)P_(m)) of Point of Contact

[0335]FIG. 18 shows a line of contact PP_(m) and a common normal n_(m)(P_(m0)P_(m)) at the point of contact P_(m). It is assumed that the gear II has rotated by the θ₂ and the point of contact is positioned at the point P on the path of contact g₀. The point of contact P_(m) other than the P is set on the tooth surface II, and the relative velocity of the point of contact P_(m) is designated by V_(rsm), and the common normal of the point of contact P_(m) is designated by n_(m)(|η_(m)|=1). If the intersection point of the n_(m) with the plane S_(H) is designated by P_(m0) and the relative velocity of the point P_(m0) is designated by V_(rsm0), because the P_(m) is a point of contact, the following relational expressions hold true.

n _(m) ·V _(rsm) =n _(m)·(V _(rsm0)+ω_(r) ×[P _(m0) P _(m) ]·n _(m))=n _(m) ·V _(rsm0)=0

[0336] where [P_(m0)P_(m)] indicates a vector having the P_(m0) as its starting point and the P_(m) as its end point.

[0337] Because the relative velocity V_(rsm0) is located on the plane S_(pm) passing at the P_(m0) and being parallel to the plane S_(p), an inclination angle on the plane S_(pm) to the plane S_(H) is designated by ψ_(m0). If a plane passing at the point P_(m0) and being perpendicular to the V_(rsm0) is designated by S_(nm), the plane S_(nm) includes the n_(m)(P_(m0)P_(m)). Consequently, the plane S_(nm) is a normal plane (the helical angle thereof:ψ_(m0)) at the point P_(m). On the other hand, because the point of contact P_(m) and the common normal n_(m) thereof are located on the plane G_(2m) inclining by the ξ₂ from the plane of action G₂₀ passing at the P₀, the inclination angle of the n_(m) expressed by the coordinate system O₂ is given by n_(m)(φ₂₀+ξ₂, ψ_(b20)). Because the common normal n_(m) is located on the line of intersection of the plane S_(m) and the G_(2m), the helical angle ψ_(m0) of the plane S_(nm) can be expressed as follows by the use of the transformation expression (40) of the inclination angle between the coordinate system C_(s) and the coordinate system O₂

tan ψ_(m0)= tan (φ₂₀+ξ₂)sin Γ_(s)− tan ψ_(b20) cos Γ_(s)/cos (φ₂₀+ξ₂)

[0338] When the position of the point P_(m0) is designated by P_(m0)(u_(cm0), 0, z_(cm0)) using the coordinate system C_(s), the following expressions (56) can be obtained from the relational expression (34) of the ψ_(m0) and the u_(cm0).

u _(cm0) =O _(m) P _(m0) =E tan ψ_(m0) sin(Σ−Γ_(s))sin Γ_(s)/sin Σ

z _(cm0) =C _(S)O_(m)  (56)

[0339] If the point P_(m0) is transformed from the coordinate system C_(s) to the coordinate system O₂ and is expressed by P_(m0)(u_(2m0), −v_(cs2), z_(2m0)), the point P_(m0) can be expressed as follows,

i u_(2m0) =−u _(cm0) cos Γ_(s) +z _(cm0) sin Γ_(s)

v _(cs2) =E tan Γ_(s)/{tan(Σ−Γ_(s))+tan Γ_(s)}

z _(2m0) =−u _(cm0) sin Γ_(s) −z _(cm0) cos Γ_(s) −z _(2cs)

z _(2c0) =−u _(c0) sin Γ_(s) −z _(c0) cos Γ_(s)  (57)

[0340] where the u_(c0) and the z_(c0) are the u_(c) and the z_(c) coordinate values of a design reference point P₀.

[0341] If the z_(cm0) is eliminated from the expressions (57), the following expression can be obtained.

u _(2m0) cos Γ_(s)+(z _(2m0) +z _(2cs))sin Γ_(s) =−u _(cm0)  (58)

[0342] The expression (58) indicates the locus P₀P_(m0) of the common normal n_(m) of the point of contact on the plane S_(H). Because P_(m0) is an intersection point of the locus P₀P_(m0) (the aforesaid expression (58)) and the line of intersection H_(g2m) of the plane of action G_(2m) and the plane S_(H), P_(m0) can be expressed as follows by the coordinate system O₂ by the use of ξ₂ as a parameter.

u _(2m0) =R _(b20)/cos(φ₂₀+ξ₂)−v _(cs2) tan(φ₂₀+ξ₂)

v _(cs2) =E tan Γ_(s)/{tan(Σ−Γ_(s))+tan Γ_(s)}

z _(2m0) =−z _(2c0)−(u _(2m0) cos Γ_(s) +u _(cm0))/sin Γ_(s)  (59)

[0343] If the point P_(m0) is expressed by P_(m0) (q_(2m0), −R_(b20), z_(2m0)) by the use of the coordinate system O_(q2), q_(2m0) can be expressed as follows.

q _(2m0) =u _(2m0) cos χ_(2m) −vcs2 sin χ_(2m)

χ_(2m)=π/2−φ₂₀−ξ₂=χ₂₀−ξ₂

[0344] With these expressions, the common normal n_(m) can be expressed on the plane of action G_(2m) by the use of ξ₂ as a parameter as a directed straight line passing at the point P_(m0) and having an inclination angle of n_(m)(φ₂₀+ξ₂, ψ_(b20)).

[0345]16.2 Equations of Line of Contact and Surface of Action

[0346]FIG. 19 shows relationships among points Q_(mo)(P_(m0)), Q_(m)(P_(m)), Q and the point P on the plane of action G₂₀. If the P_(m0) and the P_(m0) are expressed by a rotary coordinate system O_(r2m), the plane of action G_(2m) rotates by the phase difference ξ₂ to be superposed on the plane of action G₂₀. The n_(m) moves to the n, and the P_(m0) moves to the Q_(m0), and the P_(m) moves to the Q_(m). If the line of intersection of the tooth surface II and the plane of action G₂₀ is designated by w and the intersection point of w and n is designated by Q, the following relationship is concluded between the known points Q_(mo)(q_(2m0), −R_(b20), z_(2m0)) and P (q_(2p), −R_(b20), z_(2p)) and an unknown point Q{q₂(θ₂, ξ₂), −R_(b20), z₂ (θ₂, ξ₂)} by means of the coordinate system O_(q2).

z _(2m0) =−{q ₂(θ₂, ξ₂)−q _(2m0} tan ψ) _(b20) +{q _(2p) −q ₂(θ₂, ξ₂)}/tan ψ_(b20) +z _(2p)

[0347] Consequently, the point Q can be expressed as follows by means of the coordinate system O_(q2),

q ₂(θ_(2,ξ) ₂)=(q _(2m0) tan ψ_(b20) +(q _(2p)/tan ψ_(b20) +z _(2p) −z _(2m0))/(tan ψ_(b20)+1/tan ψ_(b20))

z ₂(θ₂,ξ₂)=z _(2p) +{q _(2p) −q ₂(θ₂,ξ₂)}/tan ψ_(b20)  (60)

[0348] where

[0349] q_(2p)=q_(2p0)+R_(b20)θ₂ cos² ψ_(b20)

[0350] z_(2p)=R_(b20θ) ₂ cos ψ_(b20) sin ψ_(b20).

[0351] The point Q_(m) can be expressed as follows by means of the coordinate system O_(q2) by the use of the ξ₂ as a parameter.

q _(2m)(θ₂,ξ₂)=q ₂(θ₂, ξ₂)+R _(b20)ξ₂ cos²ψ_(b20)

z _(2m)(θ₂,ξ₂)=z ₂(θ₂,ξ₂)+R _(b20)ξ₂ cos ψ_(b20) sin 9ψ_(b20)

[0352] Consequently, if the point of contact P_(m) is expressed as P_(m)(u_(2m), v_(2m), z_(2m)) by the coordinate system O₂, each coordinate value is concluded as follows by means of the expressions (55) by the use of the ξ₂ as a parameter.

χ_(2m)=χ₂₀−ξ₂=π/2−φ₂₀−ξ₂

q _(2m)(θ₂,ξ₂)=q _(2m)(θ₂,ξ₂)+R _(b20)ξ₂cos²ψ_(b20)

u _(2m)(θ₂,ξ₂)=q_(2m)(θ₂,ξ₂)cos χ_(2m) +R _(b20) sin χ_(2m)

v _(2m)(θ₂,ξ₂)=q _(2m)(θ₂,ξ₂)sin χ_(2m) −R _(b20) cos χ_(2m)

z _(2m)(θ₂,ξ₂)=z ₂(θ₂,ξ₂)+R _(b20)ξ₂ cos ψ_(b20) sin ψ_(b20)  (61)

[0353] The expressions (61) are the equations of the line of contact (PP_(m)) at the arbitrary rotation angle θ₂ in the coordinate system O₂ using ξ₂ as a parameter. The parameter a₂₀ of the aforesaid expressions (55) is a function of ξ₂ from the requirement for contact. Consequently, by changing θ₂, the surface of action can be expressed as a set of lines of contact. Furthermore, when the aforesaid expressions (61) are the equations of the common normal n_(m) (P_(m0)P_(m)) using θ₂ at the arbitrary ξ₂ as a parameter, the expressions (61) can express the surface of action as a set of the common normals n_(m) by changing ξ₂. If an involute helicoid is used as the tooth surface II, the surface of action is a distorted curved surface drawn by the directed straight line (P_(m0)P_(m)) of the helical angle ψ_(b20) on the plane of action by changing the inclination angle φ₂₀+ξ₂ of the directed straight line with the displacement of the gear II in the axis direction-

[0354] 17. Equations of Tooth Surface I Generated by Tooth Surface II

[0355]FIG. 20 shows the point of contact P_(m) and the common normal n_(m)(P_(m0)P_(m)) in the coordinate systems O₁ and O_(q1). When the point of contact P_(m) given by the aforesaid expressions (61) is expressed by the coordinate systems O₁, O_(q1) to be transformed into the coordinate system O_(r1), the transformed point of contact P_(m) expresses the tooth surface I. Because the point P_(m) is given as P_(m)(u_(2m), v_(2m), z_(2m)) by the aforesaid expressions (61), if the point P_(m) is expressed as P_(m)(u_(1m), v_(1m), z_(1m)) on the coordinate system O₁, each coordinate value can be expressed as follows by coordinate transformation expressions of the coordinate systems O₂ and O_(1.)

u _(1m) =−u _(2m) cos Σ−(z _(2m) +z _(2c0)) sin Σ

v _(1m) =v _(2m) +E

z _(1m) =u _(2m) sin Σ−(z _(2m) +z _(2c0))cos Σ−_(1co)

z ₁₀ =−u _(c0) sin(Σ−Γ_(s))+z_(c0) cos(Σ−Γ_(s))

[0356] Because the inclination angle of the common normal n_(m) is given as n_(m) (φ₂₀+ξ₂, ψ_(b20)) the n_(m) (φ_(1m), ψ_(b20)) can be obtained as follows by means of the aforesaid expressions (41) and (42), which are transformation expressions of the inclination angles between the coordinate systems O₂ and O₁.

tan_(φ1m)=tan(φ₂₀+ξ₂)sin (Σ−π/2)−tan ψ_(b20) cos(τ−π/2)/cos(φ₂₀+ξ₂)

sin ψ_(b1m)=cos ψ_(b20) sin(φ₂₀+ξ₂)cos(τ−π/2)+sin ψ_(b20) sin(Σ−π/2)

[0357] If a plane of action including the common normal n_(m) is designated by G_(1m) and the point P_(m) is expressed as P_(m)(q_(1m), −R_(b1m), z_(1m)) in the coordinate system O_(q1), the P_(m) can be expressed as follows by means of the expression (52), being the transformation expression between the coordinate systems O₁ and O_(q1).

q _(1m) =u _(1m) cos χ_(1m) +v _(1m) sin χ_(1m)

R _(b1m) =u _(1m sin χ) _(1m) −v _(1m cos χ) _(1m)

χ_(1m)=π/2−φ_(1m)

[0358] If the point P_(m) is transformed into the coordinate system O_(r1), a conjugate tooth surface I can be expressed as follows.

θ₁ =i ₀θ₂(θ₁=0 when θ₂=0)

χ_(r1m)=π/2−φ_(1m)−θ₁

u _(r1m) =q _(1m) cos φ_(r1m) +R _(b1m) sin χ_(r1m)

v _(r1m) = _(q1m) sin χ_(r1m) −R _(b1m) cos χ_(r1m)

z _(r1m) =z _(1m)  (62)

[0359] 18. Group of Pairs of Gears Having Same Involute Helicoid for one Member (Involute Gear Group)

[0360] Assuming that the axis of the gear II, the same involute helicoids (the base cylinder radius thereof; R_(b20), the helical angle thereof:ψ_(b20)) as the tooth surface II and the point P₀ (at the radius R₂₀) on the tooth surface II are given, the point P₀ and the normal no thereof can be expressed as follows by means of the coordinate system O₂. P₀(u_(2p0), v_(2p0), 0) n₀(ϕ₂₀, ψ_(b20)) ϕ₂₀ + ɛ₂₀ = cos⁻¹(R_(b20)/R₂₀) ɛ₂₀ = tan⁻¹(v_(2p0)/u_(2p0)) $R_{20} = \sqrt{\left( {u_{2{p0}}^{2} + v_{2{p0}}^{2}} \right)}$

[0361] Because P₀ is selected on the plane S_(H) and v_(2p0)=−v_(cs2) in the present embodiment, E can be obtained by giving the shaft angle Σ and the ratio of angular velocity i₀ (or a shaft angle Σ_(s) of a relative rotation axis), and the relative rotation axis S and the mating gear axis I, i.e. a pair of gears, are determined.

[0362]FIG. 21 a conceptual drawing of an involute gear group in the case where the gear II is rotated and the point P₀ and the normal n₀ thereof are selected to be fixed at an appropriate position of the coordinate system O₂ to be a design reference point and a path of contact. Furthermore, in the figure, “S” designates a relative rotation axis of a helical gear and a worm gear (or a crossed helical gear), and “S_(b)” designates a relative rotation axis of a bevel gear, and “Shy” designates a relative rotation axis of a hypoid gear. The involute gear group changes as follows in accordance with the locations of the point P₀.

[0363] (1) The involute gear group changes according to the values of the Σ when the P₀ is located on the v₂ axis.

[0364] (a) When Σ=0 or n, the involute gear group becomes an external helical gear or an internal helical gear. In the case, Γ_(s)=0 is concluded, and the conjugate mating surface I also becomes an involute helicoid.

[0365] (b) When Σ≢0, the involute gear group becomes a worm gear or a crossed helical gear. A worm gear having an involute helicoid for either a worm or a worm wheel has been put to practical use. Especially, a pair of gears employing an involute helicoid including the tooth profile I in its mating surface I is used as an involute crossed helical gear.

[0366] (2) When the P₀ is located on the u₂ axis (P_(0B)), the involute gear group becomes a bevel gear. A bevel gear forming an involute helicoid including the tooth profile I on its mating surface also is put to practical use as a conical gear.

[0367] (3) When the P₀ is located at a position other than the positions noted above (P_(0H)), the involute gear group becomes a hypoid gear and a profile shifted worm gear or a profile shifted crossed helical gear. If the P_(0H) is selected in a zone in which |εE₂₀| is relatively small (shown in the figure), the involute gear group is meant as a hypoid gear verging on a bevel gear. And if the |ε₂₀| is selected in the vicinity of π/2 (nearby the P₀), the involute gear group is meant as a profile shifted worm gear or a profile shifted crossed helical gear.

[0368] B. Design of Hypoid Gear Having Involute Helicoid as Pinion Tooth Surface

[0369] As has been described above, Japanese Patent Laid-Open Publication No. Hei 9-53702 proposes a method for describing a design method of gears uniformly from a gear having parallel two axes such as a spur gear, a helical gear or the like, which is the most popular gear type, to a hyperboloidal gear having two axes not intersecting with each other and not being parallel to each other such as a hypoid gear. However, in the hyperboloidal gear especially, there are often cases where sufficient surface of action cannot be obtained with some combinations of selected variables.

[0370] Hereinafter, a selection method of variables for forming effective surfaces of action of a hyperboloidal gear is described.

[0371] 1. Design Method of Conventional Hyperboloidal Gear

[0372] Now, some of methods that have conventionally been used for the design of a hyperboloidal gear are simply described.

[0373] (1) Involute Face Gear

[0374] An involute face gear is a pair of gears having a pinion being an involute spur gear and a large gear forming a pinion tooth surface and a conjugate tooth surface thereof on a side face of a disk (a plane perpendicular to the axis of the disk). The involute face gear is conventionally well known, and can be designed and manufactured relatively easily to be used as a gear for light loads. Some of the involute face gears use a helical gear in place of the spur gear. However, the use of the helical gear makes the design and the manufacturing of the involute face gear difficult. Consequently, the involute face gear using the helical gear is less popular than that using the spur gear.

[0375] (2) Spiroid Gear

[0376] A reference pinion cone (or a reference pinion cylinder) is given. A tooth curve being tangent to a relative velocity on a curve (pitch contact locus) being tangent to the body of revolution of a mating gear being tangent to the reference pinion cone is set to be a pinion surface line. A pressure angle within a range from 10° to 30° on a plane including an axis as an empirical value for obtaining a gear effective tooth surface to form a pinion tooth surface, thereby realizing a mating gear. However, the pinion tooth surface is formed as a screw helicoid, unlike the involute hypoid gear of the present invention. If an involute tooth surface is employed in a pinion in the design method, there are cases where an effective tooth surface of a gear cannot be obtained to a gear having a small gear ratio, i.e. having a small-pinion diameter.

[0377] (3) Gleason Type Hypoid Gear

[0378] A Gleason type hypoid gear uses a conical surface, and both of its pinion and its gear form their teeth in a conical surface state. In the specification determining method of the expression, the helical angle ψ_(0p) (being different from the helical angle ψ₀ according to the present invention strictly) of its pinion is fixed at about 50°. A gear ratio, an offset, a gear width, all empirically effective nearby the fixed helical angle ψ_(0p), are given as standards. Thereby, specifications are generated such that an almost constant asymmetric pressure angle (e.g. 14°-24°, or 10°-28°) may be effective. That is a method, so to speak, for determining a gear shape geometrically analogous to a reference gear shape. Accordingly, when designing a hypoid gear not conforming to the standard recommended by the Gleason method (for example, a face gear having a high offset and a small helical angle), because there are no empirical values, it is first necessary to establish a new standard.

[0379] 2. Hypoid Gear Being Object

[0380] When a static space is given by means of the shaft angle Σ and the offset E and a field of a relative velocity is given by means of the gear ratio i₀ according to the method disclosed in the noted Japanese Laid-Open Patent Publication, involute helicoidal tooth surfaces D and C can be determined when the design reference point P₀ (R₂₀, ψ₀) and two tooth surface normals g_(0D)(ψ₀, φ_(n0D); C_(s)) and g_(0c)(ψ₀, φ_(n0C); C_(s)) passing at the point P₀ are given. Hereupon, the tooth surfaces D and C are a drive side tooth surface and a coast side tooth surface of a pair of gears, and the g_(0D) and the g_(0C) are normals of respective tooth surfaces, i.e. paths of contact. Although the shaft angle Σ, the offset E, the gear ratio i₀, the radius R₂₀ or R₁₀ of a design reference point are given in the aforesaid design method of a face gear, relationships among a contact state of a tooth surface and three variables of ψ₀, φ_(n0D) and φ_(n0c) are not made to be clear. Consequently, the selection cannot be executed, and there are cases wherein an effective tooth surface cannot be obtained. If a case of shaft angle Σ=90° is exemplified, in at least one of the cases where the offset E is large (E/R₂₀>0.25), where the gear ratio is small (i₀=2.5-5), and where the helical angle ψ₀ is within a range of ψ₀=35°-70°, the top of the large end of the face width became sharpened and the undercut at the small end was formed improperly and no efficient tooth surfaces D and C can be formed.

[0381] In the present embodiment, as will be described in the following, a surface of action of a pair of gears a tooth surface of one of which is an involute helicoid is obtained. Using the obtained surface of action, a selection method of three variables of ψ₀, φ_(n0D) and φ_(n0C) the effective tooth surfaces of which exist in a surface of action given by a pinion and a gear, and the specifications of teeth having no sharpened top or undercut by means of an equivalent rack, which will be described later, are determined.

[0382]FIG. 22 and the following show size specifications of a hypoid gear. shaft angle Σ    90° gear ratio i₀   4.1 instantaneous axis angle Γ_(s)  76.29° offset Σ    35 mm under the center positions of axes I and II to instantaneous axis v_(cs1) −1.965 mm v_(cs2) 33.035 mm large end radius of gear R_(2h)    95 mm small end radius of gear R_(2t)    67 mm

[0383] The coordinate systems C_(s), C₁ and C₂ are determined based on the aforesaid specifications. The gear I is supposed to be a pinion, and the gear II is supposed to be a gear. In the following is described the process of determining an involute helicoid surface of a pinion for obtaining the effective gear tooth surfaces D and C in a zone enclosed by a given large end radius and a given small end radius of a gear on a disk in the case where the pinion is formed to be a cylinder shape and the involute helicoid is given to the pinion.

[0384] 3. Equivalent Rack

[0385] In this paragraph is noted a rack (equivalent rack) moving on a plane formed by two paths of contact when the paths of contact g_(0D) and g_(0c) of the tooth surfaces D and C on the drive side and the coast side are given as the two directed straight lines intersecting at the design reference point. By use of the rack, teeth effective as the teeth of a gear can be formed in the vicinity of the design reference point. The descriptions concerning the equivalent rack in this paragraph can be applied not only to the hypoid gear but also to gears in the other expressions.

[0386] 3.1 Path of Contact g₀, φ_(n0D), φ_(n0C)

[0387] It is supposed that a path of contact to be an object is given as follows in accordance with the aforesaid Japanese Laid-Open Patent Publication.

[0388] (1) Two axes I, II, their shaft angle Σ, an offset E (≧0) and a ratio of angular velocity (gear ratio) i₀ (≧1, constant) are given, and coordinate systems C₁, C₂ are defined by the use of the two axes and the common perpendicular, and a coordinate system C_(s) is defined by the use of a relative rotation axis S and the common perpendicular. Thereby, it is possible to transform coordinate values and inclination angles of directed straight lines between the coordinate systems with each other.

[0389] (2) A path of contact g₀ having no fluctuations of a bearing load is given on the coordinate system C_(s) by a design reference point P₀(u_(c0), v_(c0), z_(c0); C_(s)) and the inclination angle g₀(ψ₀, φ_(n0); C_(s)) thereof, and coordinate systems C_(q1), C_(q2) are defined by the use of planes of action G₁₀, G₂₀ including the g₀.

[0390] (3) If the intersection points of planes of rotation of the two axes I and II passing the design reference point P₀ with each gear axis are designated by O₁, O₂, the coordinate systems C₁, C_(q1), C₂, C_(q2) are moved in each gear axis direction in parallel until their origins become O₁, O₂, and thereby coordinate systems O₁, O_(q1), O₂, O_(q2) are defined. Consequently, arbitrary points P (q₂, −R_(b2), z₂; O_(q2)) and P(u₂, v₂, z₂; O₂) on the g₀ by the coordinate systems O_(q2), O₂ can be expressed as follows by means of the expressions (49),

q ₂(θ₂)=R _(b20)θ₂ cos²ψ_(b20) +q _(2p0)

R _(b2)(θ₂)=R _(b20)

z ₂(θ₂)=R _(b20)θ₂ cos ψ_(b20) sin ψ_(b20)

χ₂(θ₂)=χ₂₀=π/2−φ₂₀

u ₂(θ₂)=q ₂(θ₂)cos χ₂₀ +R _(b20) sin χ₂₀

v ₂(θ₂)=q ₂(θ₂)sin χ₂₀ −R _(b20) cos χ₂₀  (63)

[0391] where θ₂:rotation angle of gear II

[0392] P(q₂, −R_(b2), z₂; O_(q2)):the expression of the point P₀ in the coordinate system C_(q2)

[0393] g₀(φ₂₀, ψ_(b20); O₂):the expression of the inclination angle of g₀ in the coordinate system O₂.

[0394] (4) If the point P and the inclination angles of the g₀ are transformed into the coordinate systems O₁ and O_(q1), they can be expressed as follows.

P{q ₁(θ₁), −R _(b10)(θ₁),z ₁ (θ₁);O_(q1)}

g ₀(φ₁₀,ψ_(b10);O₁)  (64)

[0395] Incidentally, θ₁=i₀θ₂.

[0396] (5) When it can be assumed that the paths of contact on the drive side and the coast side intersect with each other at the point P₀ and further are given as two directed straight lines that do not generate any undercut and interference in the vicinity of the point P₀, as described above, the expressions of the paths of contact on the drive side and the coast side by the coordinate system C_(s) can be respectively designated by g_(0D)(ψ₀; φ_(n0D); C_(s)) on the drive side and g_(0C)(ψ₀, φ_(n0C); C_(s)) on the coast side.

[0397] 3.2 Definition of Limiting Path g_(t) (Case Where Plane S_(n) Does not Include Common Perpendicular)

[0398]FIG. 23 conceptually shows relationships among planes S_(H), S_(p) and S_(n) of a hypoid gear and a plane S_(t) formed by velocities V₁₀, V₂₀ at the point P₀. Hereupon, the plane S_(H) is a V_(c)=0 plane in the coordinate system C_(s), and the plane S_(p) is a u_(C)=u_(C0) plane, and the plane S_(n) is a plane perpendicular to the relative velocity V_(rs0) at the P₀.

[0399] Because the design reference point P₀ is located on the plane S_(H), the relative velocity V_(rs0) is located on the plane S_(p). On the other hand, because the plane S_(t) also includes V_(rS0), the plane S_(t) and the plane S_(p) intersect with each other with the relative velocity V_(rs0) as a line of intersection. Furthermore, the plane S_(t) and the plane S_(n) cross with each other at right angles, and have a normal velocity V_(gt0) on the plane S_(t) as the line of intersection g_(t) (positive in the direction of the V_(gt0)). That is, the plane S_(t) is a plane formed by the rotation of the plane S_(p) around V_(rS0) as an axis on the plane S_(n) by φ_(nt), and corresponds to the conventional pitch plane.

[0400] If the intersection points of the plane S_(n) with the gear axes I, II are designated by O_(1n), O_(2n), peripheral velocities V₁₀, V₂₀ of the point P₀ are expressed as follows.

V ₂₀=ω₁₀ ×[O _(1n) P _(0])  (65)

V ₂₀ω₂₀ ×[O _(2n0P) _(0])  (65)

[0401] Here, [AB] indicates a vector having a point A as its starting point and a point B as its end point. Because O_(1n)P₀ is located on the plane S_(n), the O_(1n)P₀ is perpendicular to the relative velocity V_(rs0), and is perpendicular to the V₁₀ owing to the aforesaid expression. Consequently, the O_(1n)P₀ is perpendicular to the plane S_(t) at the point P0. Quite similarly, because O_(2n)P₀ is perpendicular to the V_(rs0) and the V₂₀, the O_(2n)P₀ is perpendicular to plane S_(t) at the point P0. In other words, the points O_(1n), P₀ and O_(2n) are located on a straight line. Accordingly, the straight line is set to be a design criterion perpendicular C_(n) (positive in the direction from the O_(1n) to the O_(2n)). The C_(n) is the line of centres of a pair of gears passing at the point P0. The relationship does not depend on the position of the point P₀.

[0402] Because an arbitrary plane including the relative velocity V_(rso) can be the tangential plane of a tooth surface passing at the point P₀, a tooth surface having a tangential plane W_(N) (perpendicular to the plane S_(t)) including the design criterion perpendicular C_(n) has the g_(t) as its path of contact (contact normal). Because, in an ordinary gear, the tangential plane of a tooth surface passing the point P0 is appropriately inclined to the plane W_(N) formed by the V_(rso) and the C_(n), the path of contact g₀ (contact normal) thereof is inclined on the plane S_(n) on the basis of the g_(t). Accordingly, if g_(t) is a limiting path g_(t), the inclination angle g_(t) (ψ₀, φ_(nt); C_(s)) of the limiting path g_(t) can be obtained as follows.

[0403]FIG. 24 draws the design criterion perpendicular C_(n) on the plane S_(n) and the limiting path g_(t) perpendicular to the C_(n). If the feet of perpendicular lines drawn from the points O_(1n), O_(2n) to the plane S_(p) (perpendicular to the plane S_(n)) are designated by O_(1np), O_(2np), the φ_(nt) can be obtained as follows. $\begin{matrix} \begin{matrix} {{\tan \quad \phi_{n1}} = \quad {{P_{0}{O_{2{np}}/O_{2{np}}}O_{2n}} = {O_{1{np}}{P_{0}/O_{1n}}O_{1{np}}}}} \\ {= \quad {v_{cs2}/\left\lbrack {\cos \quad \phi_{0}\left\{ {{\left( {z_{c0} + {v_{cs2}\tan \quad \psi_{0}}} \right)\tan \quad \Gamma_{s}} - u_{s0}} \right\}} \right\rbrack}} \\ {= \quad {{- v_{cs1}}/\left\lbrack {\cos \quad \phi_{0}\left\{ {{\left( {z_{c0} + {v_{cs1}\tan \quad \psi_{0}}} \right){\tan \left( {\Sigma - \Gamma_{s}} \right)}} + u_{s0}} \right\}} \right\rbrack}} \end{matrix} & (66) \end{matrix}$

[0404] Here, each directed line segment has its positive direction being the positive direction of the each axis of the coordinate system C_(s).

[0405] In a hypoid gear, v_(cs2), v_(cs1), u_(c0), z_(c0) can be expressed as follows by means of the coordinate systems O₁, O₂.

v _(cs2) =E tan Γ _(s)/{tan Γ_(s)+tan(Σ−Γ_(s)) }

u _(c0) =E sin(Σ−Γ_(s))sin Γ_(s) tan ψ₀/sin Σ

z _(C0)=(u _(2p0) +u _(c0) cos Γ_(s))/sin Γ_(s)

u _(2p0) =−v _(cs2)/tan ε₂₀(ε₂₀≢0)

v _(cs1) =−E tan(Σ−Γ _(s))/{tan Γ_(s)+tan(Σ−Γ_(s))}

z _(c0) ={u _(p0) −u _(c0) cos(Σ−Γ_(s))}/sin(Σ−Γ_(s))

u _(1p0) =−v _(cs1)/tan₀(ε_(10≢0))

[0406] If the u_(c0), the z_(c0), the v_(cs1) and the v_(cs2) are eliminated from the expressions (66) by the use of the above expressions and the eliminated expressions (66) is arranged, the changed expressions (66) become as follows. $\begin{matrix} {{\tan \quad \phi_{nt}} = \quad {\cos \quad {\Gamma_{s}/\left( {\cos \quad {\psi_{0}/\tan}\quad ɛ_{20}\sin \quad \Gamma_{s}\sin \quad \psi_{0}} \right)}}} \\ {= \quad {{\cos \left( {\Sigma - \Gamma_{s}} \right)}/\left\{ {{\cos \quad {\psi_{0}/\tan}\quad ɛ_{10}} - {{\sin \left( {\Sigma - \Gamma_{s}} \right)}\sin \quad \psi_{0}}} \right\}}} \end{matrix}$

[0407] The limiting path g_(t) inclines by φ_(nt) to the plane S_(p) on the plane S_(n). The φ_(nt) has its positive direction in the clockwise direction when it is viewed to the positive direction of the z_(C) axis.

[0408] 3.3 Definition of Equivalent Rack

[0409]FIG. 25 shows an equivalent rack on the plane S_(n) shown from the positive direction of the relative velocity V_(rs0). The following are shown:the peripheral velocities V₁₀, V₂₀ at the point P0, the relative velocity V_(rs0) (=V_(s10)−V_(s20)), the normal velocity V_(gt0) (in the direction of the limiting path g_(t)), the path of contact g_(0D), g_(0C) on the plane S_(n), and the tangential planes W_(D), W_(C) (shown as lines of intersection W_(SD), W_(SC) with the plane S_(n) in FIG. 25) of the tooth surfaces D, C having the g_(0d), g_(0C).

[0410] The peripheral velocities V₁₀, V₂₀ can be expressed as follows on the plane S_(t).

V ₁₀ =V _(gt0) +V _(s10)

V ₂₀ =V _(gt0) +V _(s20)

[0411] Because the tangential plane W_(D) has the relative velocity V_(rs0) in common together with the plane S_(t), the peripheral velocities V₁₀, V₂₀ can be expressed as follows,

V ₁₀=(V _(g0D) +V _(WsD))+V_(S10)

V ₂₀=(V _(g0D) +V _(WsD))+V _(S20)

[0412] where

[0413] V_(g0D):the normal velocity (in the g_(0D) direction) of tangential plane W_(D)

[0414] V_(WsD):the velocity in the W_(sD) direction on the tangential plane W_(D).

[0415] Consequently, the following relationships are always effective at the point P_(0.)

V _(gt0) =V _(g0D) +V _(WsD)

[0416] The tangential plane W_(C) can also be expressed as follows quite similarly,

V _(gt0) =V _(g0C) +V _(WsC)

[0417] where

[0418] V_(g0c):the normal velocity (in the g_(0C) direction) of the tangential plane W_(C)

[0419] V_(WsC):the velocity of the W_(sC) direction of the tangential plane W_(C).

[0420] Consequently, the normal velocities V_(g0D), V_(g0C) can be obtained as follows as the g_(0D), g_(0C) direction components of the V_(gt0).

V _(g0D) =V _(gt0) cos(φ_(n0D −φ) _(nt))

V _(g0C) =V _(gt0) cos(φ_(nt)−φ_(n0C))  (67)

[0421] On the other hand, the V_(gt0), the V_(g0D) and the V_(g0C) can be expressed as follows,

V _(gt0) =R _(b2qt)(dθ ₂ /dt)cos ψ_(b2gt)

V _(g0D) =R _(b20D)(dθ ₂ /dt)cos ψ_(b20D)

V _(g0C) =R _(b20C)(dθ ₂ /dt)cos ψ_(b20C)

[0422] where

[0423] R_(b2gt), R_(b20D), R_(b20C):the radii of the base cylinder of the gear II (large gear) of the g_(t), the g_(0D) and the g_(0C)

[0424] ψ_(b2gt), ψ_(b20D), ψ_(b20C):the inclination angles of the g_(t), the g_(0D) and the g_(0C) on the plane of action of the gear II (large gear).

[0425] Because the g_(t), the g_(0D) and the g_(0C) are straight lines fixed in static space, the normal velocities V_(gt0), V_(g0D), V_(g0C) are always constant. Consequently, the normal velocities V_(g0D), V_(g0C) of the arbitrary points P_(D), P_(C) on the g_(0D) and the g_(0C) can always be expressed by the expressions (67).

[0426] This fact means that the points of contact on the g_(0D), g_(0C) owing to the rotation of a gear are expressed by the points of contact of a rack having the g_(t) as its reference line and the same paths of contact g_(0D), g_(0C) (having the W_(sD) and the W_(sC) as its tooth profiles) and moving at V_(gt0) in the direction of the g_(t). If the rack is defined as an equivalent rack, the equivalent rack is a generalized rack of a spur gear having an involute of zero. The problems of contact of all gears (from cylindrical gears to a hypoid gear) having paths of contact given to satisfy the conditions of having no fluctuations of a bearing load can be treated as the problem of the contact of the equivalent rack.

[0427] 3.4 Specifications of Equivalent Rack

[0428] (1) Inclination Angles (Pressure Angles) of W_(SD), W_(sC) to C_(n)

[0429] The W_(sD) and the W_(sC) are inclined by (φ_(n0D)−φ_(nt)) and (φ_(nt)−φ_(n0C)) to the C_(n) (perpendicular to the g_(t)), respectively. φ_(n0D)=φn_(0C)=φ_(nt) indicates that the pressure angle of an equivalent rack is zero.

[0430] (2) Pitch P_(gt)

[0431] The limiting path g_(t) indicates the reference line of an equivalent rack, the reference pitch P_(gt) and the normal pitchs P_(n0D), P_(n0c) can be expressed as follows.

p _(gt)=2πR _(b2gt) cos ψ_(b2gt) /N ₂ (in the direction of the g_(t))

p _(g0D) =P _(gt) cos(φ_(n0D)−φ_(nt))

=2πR _(b20D) cos ψ_(b20D) /N ₂ (in the direction of the g_(0D))

p _(g0c) =p _(gt) cos(φ_(nt)−φ_(n0C))

=2πR _(b20C) cos ψ_(b20C) /N ₂ (in the direction of the g_(0C))  (68)

[0432] Incidentally, N₂ is the number of teeth of the gear II.

[0433] (3) Working Depth h_(k)

[0434] In FIG. 25, if a position distant from the W_(sD) by a pitch (1 P_(g0D)) is designated by w_(sDA) and the intersection point of the W_(sC) with the W_(sD) and the W_(sDA) are designated by R_(CD) and R_(CDA), a critical tooth depth her (R_(CD)R_(CDH)), at which the top land of the equivalent rack is zero, can be expressed as follows with attention to the fact that the R_(CD)R_(CDH) crosses with the g_(t) at right angles.

H _(cr) =R _(CD) R _(CDH) =p _(g0D) cos(φ_(nt −φ) _(n0C))/sin(φ_(n0D)−φ_(nt))

[0435] If the cutter top land on the equivalent rack is designated by t_(cn) and the clearance is designated by C_(r), the working depth h_(k) (in the direction of the C_(n)) of the equivalent rack can be expressed as follows.

h _(k) =h _(cr)−2t _(cn)/{ tan(φ_(n0D)−φ_(nt))+tan(φnt−φ_(n0C))}−2C _(r)  (69)

[0436] (4) Phase Angle of W_(sC) to Design Reference Point p₀ (W_(sD))

[0437] In FIG. 25, Q_(1n), Q_(2n) are set in the vicinity of the point P₀ on the C_(n) such that h_(k)=Q_(1n)Q_(2n), and addendums A_(d2), A_(d1) are defined as follows.

[0438] P₀Q_(2n)=A_(d2) (the addendum of the gear II)

[0439] P₀Q_(1n)=A_(d1)=h_(k)−A_(d2) (the addendum of the gear I)

[0440] It should be noted that it is here assumed that the point Q_(2n) is selected in order that both of the paths of contact g_(0D), g_(0C) may be included in an effective zone and the A_(d2)≧0 when the Q_(2n) is located on the O_(1n) side to the point P₀.

[0441] If the intersection point of the g_(0C) with the W_(sC) is designated by P_(c), P₀P_(c) can be obtained as follows.

P ₀ P _(C) =−{A _(d2)+(h _(cr) −h _(k))/2} sin(φ_(n0D)−φ_(n0C))/cos(φ_(n0D)−φ_(nt))

[0442] Incidentally, the positive direction of the P₀P_(C) is the direction of g_(0C).

[0443] Because the rotation angle θ₂ of the point P₀ is zero, the phase angle θ_(2wsC) of the point P_(C) becomes as follows,

θ_(2wsC)=(P ₀ P _(C) /P _(g0C))(2θ_(2p))  (70)

[0444] where the 2θ_(2p) is the angular pitch of the gear II. The W_(sC) is located at a position delayed by θ_(2wsC) to the W_(sD). Thereby, the position of the W_(sC) to the point P₀ (W_(sD)) has been determined.

[0445] Because the phase angle of the W_(sC) to the W_(sD) is determined by the generalization of the concept of a tooth thickness in the conventional gear design (how to determine the tooth thickness of a rack on the g_(t)), the phase angle is determined by giving a working depth and an addendum in the present embodiment.

[0446] 4. Action Limit Point

[0447] A tooth profile corresponding to an arbitrarily given path of contact exists mathematically. However, only one tooth profile can actually exist on one radius arc around a gear axis at one time. Consequently, a tooth profile continuing over both the sides of a contact point of a cylinder having the gear axis as its axis with a path of contact does not exist actually. Therefore, the contact point is the action limit point of the path of contact. Furthermore, this fact indicates that the action limit point is the foot of a perpendicular line drawn from the gear axis to the path of contact, i.e. the orthogonal projection of the gear axis.

[0448] If an intersection point of a path of contact with a cylinder (radius:R₂) having the gear axis as its axis is designated by P, the radius R₂ can be expressed as follows.

R ₂ ² =q ₂ ² +R _(b2) ²

[0449] If the point of contact P is a action limit point, the path of contact and the cylinder are tangent at the point P. Consequently, the following expression holds true.

R ₂(dR ₂ /dθ ₂)=q ₂(dq ₂ /dθ ₂)+R _(b2)(dR _(2b) /dθ ₂)=0

[0450] If the (dq₂/dθ₂) is eliminated by means of the expression (7), the result becomes as follows.

q ₂(1−dχ ₂ /dθ ₂)/(tan ψ_(b2) tan η_(b2)+1)+dR _(b2) /dθ ₂=0

[0451] Hereupon, because the g_(0D) and the g_(0C) are supposed to be a straight line coinciding with a normal, dχ₂/dθ₂=0, dR_(2b)/dθ₂=0. The expression can then be simplified to q₂=0.

[0452] If the expression is solved for θ₂, an action limit point P_(2k) concerning the gear II can be obtained. An action limit point P_(1k) concerning the gear I can similarly be obtained by solving the equation q₁=0 after simplifying the following expression.

q ₁(1−dχ ₁ /dθ ₁)/(tan ψ_(b1) tan η_(b1)+1)+dR _(b1) /dθ ₁=0

[0453] 5. Selection of Design Reference Point P₀ and Inclination Angle ψ₀ of Plane S_(n) in Hypoid Gear

[0454] For a pair of gears having parallel gear axes, the shape of a surface of action is relatively simple, and there is no case where it becomes impossible to form any tooth surface according to the setting way of a design reference point P₀ as long as the design reference point P₀ is located within an ordinary range. Furthermore, even if no tooth surface can be formed by a given design reference point P₀, amendment of the design reference point P₀ remains relatively easy.

[0455] Because the surface of action of a hypoid gear is very complicated, as will be described later, it is difficult to determine how to alter the surface of action to form an effective tooth surface. Hereinafter, a method for designing a hypoid gear effectively, i.e. the selection method of specifications, is described.

[0456]FIG. 26 shows relationships among limiting paths g_(2z), g_(t), paths of contact g_(0D), g_(0C) and their equivalent rack on the plane S_(n). Hereupon, the limiting path g_(2z) is a line of intersection of the plane S_(n) with a right side plane Z₂₀ immediately below the gear axis, and the limiting path g_(t) is a line of intersection of the plane S_(n) with a plane S_(t) forming the line velocity of the point P₀. The selection of the design reference point P₀ is the selection of a position in a static space where the shape of the equivalent rack is given. In the present embodiment, it is supposed that a pinion has a cylindrical shape and the shape of the teeth of the pinion is constant (only the phase angles thereof change) in the direction of the axis thereof. The shape of teeth of a gear changes from the small end thereof to the large end thereof. Then, the design reference point P₀ is selected at the center of the face width of the gear. That is, the radius R₂₀ of the design reference point P₀ to the gear axis becomes as follows.

R ₂₀=(R _(2h) +R _(2t))/2  (71)

[0457] For forming an effective tooth surface with a given small end and a given large end of a large gear, there is a case where it is necessary to amend the shape of an equivalent rack or the position of the design reference point P₀. Consequently, the expression (71) can be considered to give a first rank approximation of the R₂₀.

[0458] Each ψ₀ being inclinations of the plane S_(n) perpendicular to the relative velocity at the design reference point P₀ is selected as follows. Because the line of intersection of the plane S_(n) with the plane of rotation Z₂₀ of the gear axis passing the point P₀ is the limiting path g_(2z), the inclination angles g_(2z)(ψ₀, φ_(n2z); C_(s)) and g_(2z)(φ_(2z), 0; C₂) of the limiting path g_(2z) can be obtained from the following expressions.

tan φ_(n2z)=sin ψ₀/tan Γ_(s)

tan φ_(2z)=tan 104 ₀/sin Γ_(s)  (72)

[0459] Because the face and root surface of a large gear are formed as planes of rotation of gear in the present embodiment, the tangential planes of tooth surface of a large gear should be inclined mutually in the reverse directions to the plane of rotation of the large gear to each other in order that a tooth of the large gear may have an ordinary shape of a trapezoid. Consequently arbitrary paths of contact g_(0D) and g_(0C) should be located in the vicinity of the limiting path g_(2z) and should be inclined in the mutually reverse directions to the g_(2z). Because the active limit radii (base circle radii) R_(b20D), R_(b20C) of the paths of contact g_(0D), g_(0C) on the gear side are near to the base cylinder radius R_(b2z) of the limiting path g_(2z), the tooth surface of the gear should approximately satisfy the following relationships in order that the tooth surface may be effective at a radius equal to the small end radius R_(2t) of the gear or more.

R _(2t) ≧R _(b2z) =R ₂₀ cos(φ_(2z)+ε₂₀)

sin ε₂₀ =−v _(cs2) /R ₂₀  (73)

[0460] Incidentally, ε₂₀=0 in case of a bevel gear.

[0461] From the expressions (72), (73), the ψ₀ can be obtained. Because, if i₀ is large, φ_(2z)≈ψ₀ from the expressions (72) and the expressions (73) maybe replaced with the following expression.

R _(2t) >R ₂₀ cos(φ_(2z)+ε₂₀)  (74)

[0462] From the R₂₀ and the ψ₀, the design reference point P₀ and the limiting paths g_(2z), g_(t) are determined on the plane S_(H) by the coordinate system C_(s) as follows. P₀(u_(c0), 0, z_(c0); C_(s)) g_(2z)(ψ₀, ϕ_(n2z); C_(s)) g_(t)(ψ₀, ϕ_(nt); C_(s)) u_(c0) = E  sin   Γ_(s)cos   Γ_(s)tan   ψ₀ $z_{c0} = {{\left\{ {\sqrt{\left( {R_{20}^{2} - v_{cs2}^{2}} \right)} + {u_{c0}\cos \quad \Gamma_{s}}} \right\}/\sin}\quad \Gamma_{s}}$ tan   ϕ_(n1) = cos   Γ_(s)/(−cos   ψ₀/tan   ɛ₂₀ + sin   Γ_(s)sin   ψ₀)

[0463] The R₂₀ and the ψ₀ determined as described above should be regarded as first rank approximates, and there are cases where the R₂₀ and the ψ₀ are adjusted according to the state of the tooth surface obtained as a result of the method described above. Furthermore, if needed values of an offset and a face width of a large gear are too large, there are cases wherein suitable R₂₀ and ψ₀ giving a satisfactory tooth surface do not exist.

[0464] If the coordinate systems O₁, O_(q1), O₂, O_(q2) are fixed, the design reference point P₀ and the inclination angles of the limiting paths g_(2z), g_(t) can be expressed in each coordinate system.

[0465] 6. Paths of Contact g_(0D), g_(0C)

[0466] 6.1 Domain of φ_(n0D), φ_(n0C) on Plane S_(n)

[0467] It is preferable that the tangential planes W_(sD) and W_(sC) of a tooth surface of a gear are inclined to the plane of rotation of gear Z₂₀ in the mutual reverse directions in order that the teeth of the gear may have a necessary strength. Consequently, the paths of contact g_(0D), g_(0C) should be selected to be inclined to the limiting path g_(2z) in the mutual reverse directions. That is, the inclinations of the paths of contact g_(0D), g_(0C) are selected to satisfy the following expression.

φ_(n0C)≦φ_(n2z)≦φ_(n0D)  (75)

[0468] Moreover, if it is supposed that the paths of contact g_(0D), g_(0C) form an equivalent rack having a vertex angle of 38° on the plane S_(n), the following expression is concluded.

φ_(n0D)−φ_(n0C)=38°  (76)

[0469] The combinations of the φ_(n0D) and the φ_(n0C) can be expressed by the following three ways or nearby cases from the expressions (75) and (76).

φ_(n0C)=φ_(n2z),φ_(n0D)=φ_(n2z)+38°  A.

φ_(n2z)=φ_(n0D),φ_(n0C)=φ_(n2z)−38°  B.

φ_(n0C)=φ_(n2z)−19°φ_(n0D)=φ_(n2z)+19°  (77)

[0470] 6.2 Surface of Action and Action Limit Curve of Involute Helicoid

[0471] FIGS. 27-30 show surfaces of action in a case where a pinion is given an involute helicoid (the base cylinder radius thereof: R_(b12z), the plane of action helical angle thereof:ψ_(b12z)) the tooth surface normal of which is the limiting path g_(2z). FIG. 27 is a sketch map for making the whole shape of a curved surface to be easy to understand. The expression of a surface of action is quite similar to that in the case where an involute helicoid is given to a large gear, the expression can be obtained by replacing the suffix 2 in the expressions (61) with 1.

[0472] A surface of action is expressed by paths of contact and lines of contact almost perpendicular to the paths of contact, and is composed of a curved surface (surface of action C) drawn by the movement of the path of contact from the g_(2z) (φ_(12z)=0) toward the z₁ (>0) direction while rotating in the φ₁ (>0) direction, and a curved surface (surface of action D) drawn by the movement of the path of contact toward the z₁ (>0) direction while rotating in the φ₁ (<0) direction. Only a tooth surface normal that satisfies the requirement for contact among the tooth surface normals of the involute helicoid becomes a contact normal. A tooth surface normal can be a contact normal at two positions of the both sides of the contact point to the base cylinder. Consequently, the curved surfaces shown in FIGS. 28-30 are drawn.

[0473] Loci of action limit curve (action limit point) of a pinion and a large gear of paths of contact are designated by L_(1A) (on a pinion base cylinder), L_(2AD) and L_(2AC). Furthermore, orthogonal projections (action limit point on the gear axis side) to the surfaces of action of the large gear axis are designated by L_(3AD) and L_(3AC) which are the loci of the contact point of a cylinder having the large gear axis as its axis with an intersection line of the surface of action with a plane of rotation Z₂. Because the surface of action is determined by the involute helicoid given to the pinion side in the present embodiment, the orthogonal projection to the surface of action of the pinion axis (the action limit curve on the pinion side) is the L_(1A). In cylindrical gears, the surface of action becomes a plane, such that consequently the orthogonal projection of the surface of action of a pinion axis and a large gear axis become a simple straight line. However, because the surfaces of action of hypoid gears are complicated curved surfaces as shown in the figures, the orthogonal projections of a pinion axis and a large gear axis do not become a straight line. And there are a plurality of the orthogonal projections for each the axes. Moreover, there is also a case where the orthogonal projections generate ramifications. A zone enclosed by a action limit curve nearest to the design reference point P₀ is a substantially usable tooth surface.

[0474] Moreover, the face surface of the gear is designated by Z_(2h) (=0) (the plane of rotation of the gear including g_(2z)). The large end of the large gear and the line of intersection of the small end cylinder with the surface of action are designated by R_(2h), R_(2t), respectively.

[0475] Because a surface of action including the limiting path g_(2z) and enclosed by the L_(3AD) and the L_(3AC) is limited to a narrow zone near to the P₀, there is no tooth surface that can substantially be used. Accordingly, an effective surface of action enclosed by the action limit curve, the face surface of the large gear, and large end and small end cylinders are as described in the following.

[0476] EFFECTIVE SURFACE OF ACTION C_(eff):a zone (convexo-concave contact) enclosed by the action limit curve L_(3AC) on the surface of action C and the boundary lines of the gear Z_(2h) (=0) and R_(2h).

[0477] EFFECTIVE SURFACE OF ACTION D_(eff):a zone (convexo-convex contact) enclosed by boundary lines of the gear z_(2h) (=0), R_(2h), R_(2t) on the surface of action D.

[0478] 6.3 Selection of Paths of Contact g_(0D), g_(0C)

[0479] (1) In Case of Expression (77)A

[0480] The case of the expression (77)A is one wherein the path of contact g_(0C) is taken as the g_(2z), and, in the case the effective surface of action C_(eff), is given by FIGS. 28-30. Because the boundary of the effective surface of action C_(eff) on the small end side of the large gear is determined by the action limit curve L_(3AC), there is no tooth surface of the large gear on the small end side of the large gear from the L_(3AC). Consequently, it is necessary to set the zones (R_(2t)-R_(2h)) of the gear to the larger end side in accordance with the effective surface of action C_(eff) again for realizing the tooth surface C as it is.

[0481] (2) In Case of Expression (77)B

[0482] The case of the expression (77)B is one wherein the path of contact g_(0D) is taken as the g_(2z), and, in the case the effective surface of action D_(eff), is also given by FIGS. 28-30. Because the lines of intersection z_(2h) (=0), R_(2t), R_(2h) of the boundary surface of the large gear with the surface of action are located in the inner from the action limit curves L_(1A), L_(3AD), L_(2AD), the combination of the expression (77)B can realize an effective tooth surface D in the inner of the zone (R_(2t)-R_(2h)) of the given large gear.

[0483] FIGS. 31-33 shows the effective surface of action C_(eff) of the tooth surface C (φ_(n0C)=φ_(n2z)−38°) at this time. Because the base cylinder radius R_(b10C) of the g_(0C) becomes small, the L_(3AC) moves to the inner of the large gear, and it is known that the L_(3AC) is pretty improved in comparison with the C_(eff) shown in FIGS. 28-30 when they are compared at the position of the point P₀. Consequently, it is shown that the tooth surface C can almost be realized in the zone of the large gear (R_(2t)-R_(2h)) by slightly altering g_(0C).

[0484] (3) In Case of Expression (77)C

[0485] For ensuring the effective surface of action C_(eff) (convexo-concave contact) in the vicinity of the design reference point P₀, as described above, it is necessary to incline g_(0C) from g_(2z) as large as possible to make the radius of the base cylinder of a pinion small for locating the L_(3AC) on the small end side of the large gear (in the inner thereof if possible). On the other hand, to make the shape of the base cylinder small by inclining g_(0D) from g_(2z) by as much as possible results only in a decrease of the contact ratio, which is of little significance. In particular, if the tooth surface D is used on the drive side as in a hypoid gear for an automobile, it is rather advantageous to bring g_(0D) as close as possible to g_(2z). For making both of the tooth surface D and the tooth surface C effective in the given large gear zone (R_(2t)-R_(2h)), the selection near to the expression (77)B (R_(b10D)>R_(b10C)) is advantageous in almost all cases.

[0486] In the pair of gears having an involute helicoid as the tooth surface of a pinion described above, it is necessary that the action limit curve (L_(3AC) in this case) on the convexo-concave contact side is brought to the inner from the small end of the large gear, which is a cause of employing unsymmetrical pressure angles (different base cylinders).

[0487] On the basis of the examination mentioned above, each of the inclination angles of the paths of contact g_(0D , g) _(0C) is determined as follows.

g _(0D)(ψ₀,φ_(n0D)=φ_(n2z) ;C _(s))

g _(0C)(ψ₀,φ_(n0C)=φ_(n2z)−38°; C _(s))  (78)

[0488] Here, it is practical to set the φ_(n0D) larger than the φ_(2z) a little for giving an allowance.

[0489] 7. Boundary Surfaces of Equivalent Rack and a Pair of Gears

[0490] 7.1 Specifications of Equivalent Rack

[0491]FIG. 26 shows the shape of an equivalent rack on the plane S_(n). If a design reference point P₀, a reference line (limiting path) gt of the equivalent rack and paths of contact g_(0D), g_(0C) are given, the specifications and a position of the equivalent rack to the design reference point P₀ can be obtained as follows.

[0492] (1) Normal Pitches P_(g0D), P_(g0C)

p _(g0D)=2πR _(b10D) cos ψ_(b10D) /N ₁ (in the direction of g_(0D))

p _(g0C)=2πR _(b10C) co ψ_(b10C) /N ₁ (in the direction of g_(0C))  (79)

[0493] where

[0494] N₁:the number of teeth of the gear I.

[0495] (2) Working Depth h_(k)

h _(k) =p _(g0D) cos(φ_(nt)−φ_(n0C))/sin(φ_(n0D)−φ_(n0C))−2t _(cn)/{ tan(φ_(n0D)−φ_(nt))+tan(φ_(nt)−φ_(n0C))}  (80)

[0496] where

[0497] t_(cn):the cutter top land on the equivalent rack

[0498] c_(r):clearance.

[0499] (3) Addendum A_(d2) of Large Gear

P ₀ Q _(2n) A _(b2)=(u _(1p0) −R _(b10D))sin(φ_(n0Dl −φ) _(nt))/cos φ_(10D)/cos ψ_(b10D)

P ₀ Q _(1n) =A _(d1) =h _(k) −A _(d2)  (81)

[0500] (4) Phase Angle θ_(2wsC) of W_(sC) to Point P₀ (W_(sD))

[0501] ti θ_(2wsC)=−2θ_(2p) {A _(d2)+(h _(cr) −h _(k))/2} sin(φ_(n0D)−φ_(n0C))/cos(φ_(n0D)−φ_(nt))/p_(g0C)  (82)

[0502] where

[0503] 2θ_(2p):the angular pitch of the large gear.

[0504] 7.2 Face Surface of Large Gear

[0505] Because the paths of contact g_(0D), g_(0C) mutually incline in opposite directions to each other to the plane of rotation of large gear, it is advantageous for the face and root surfaces of a large gear to be planes of rotation of the large gear rather than to be a conical surface for realizing both of them reasonably. Accordingly, the plane of rotation of the gear passing the point Q_(2n) is supposed to be the face surface of gear as follows,

face surface of gear z _(2h) =z _(2Q2n)  (83)

[0506] where Q_(2n) (u_(2Q2n), v_(2Q2n), z_(2Q2n); O₂).

[0507] 7.3 Pinion Face Cylinder

[0508] If a pinion face surface is supposed to be a cylinder passing the point Q_(1n) in accordance with the large gear face surface, the pinion face cylinder radius can be expressed as follows,

R _(1Q1n)={square root}{square root over ((u _(1Q1n) ² +v _(1Q1n) ²))}  (84)

[0509] where Q_(1Q)(u_(1Q1n), v_(1Q1n), z_(1Q1n); O₂).

[0510] 7.4 Inner and Outer Ends of Pinion

[0511] The outer and the inner ends of a pinion are supposed to be planes of rotation of the pinion passing intersection points of a large end cylinder and a small end cylinder of the large gear with the axis of the pinion. Consequently, the outer and the inner ends of the pinion can be expressed as follows in the coordinate system O₁,

pinion outer end z _(1h)={square root}{square root over ((R _(2h) ² −E ²)})−z _(1c0)

pinion inner end z _(1t)={square root}{square root over ((R _(2t) ² −E ⁷))}−z _(1c0)  (85)

[0512] where

[0513] z₁₀:a transformation constant from the coordinate system C₁ to the O_(1.)

[0514] 8. Modification of Pinion Involute Helicoid

[0515] The pinion involute helicoid determined as above has the following practical disadvantages in the case where the tooth surfaces D, C severally have leads different from each other. In the case where the face surface of pinion is a cylinder, for example, the pinion top land may not be constant, and it may be necessary to determine the location of the pinion in the axial direction and to manufacture tooth surfaces separately, and so forth. Accordingly, in the present embodiment, the pinion involute helicoid is somewhat modified as follows for making the leads of the tooth surfaces D and C equal. Various methods for making the leads of the toothsurfaces D and C equal can be considered. Hereupon, it is supposed that the tooth surface D is left to be the given original form, and that tooth surface C is changed to be a tooth surface C_(c) by the adjustment of only its helical angle ψ_(b10C) (with base cylinder radius R_(b10C) being left as it is)

[0516] (1) Helical Angle ψ_(b10CC) of Tooth Surface C_(c)

[0517] Because the lead of the tooth surface C_(c) is the same as that of the tooth surface D, the helical angle ψ_(b10CC) can be obtained from the following expression.

tan ψ_(b10CC) =R _(b10C) tan ψ_(b10D) /R _(b10D)  (86)

[0518] (2) Path of Contact g_(0CC) of Gear C_(c)

[0519] If the contact normal of a tooth surface C_(c) on the plane of action G_(10C) of the tooth surface C passing the design reference point P₀ is newly designated by a path of contact g_(0CC), the inclination angle thereof can be expressed as follows.

g _(0CC)(φ_(10C),ψ_(b10CC);O₁)  (87)

[0520] Consequently, the intersection point P_(0CC)(u_(c0CC), 0, z_(c0CC); C_(s)) thereof with the plane S_(H) expressed by the coordinate system C_(s) can be obtained from the following expressions.

sin φ_(n0CC)=−cos ψ_(10CC) sin φ_(10C) sin ψ_(b10CC) cos Γ_(s)

tan ψ_(0CC)=tan φ_(10C) cos Γ_(s)+tan ψ_(b10CC) sin Γ_(s)/cos φ_(10C)

u _(c0CC) =E tan ψ_(0CC) cos Γ_(s) sin Γ_(s)

z _(c0CC)=(u _(1p0) −u _(c0CC) sin Γ_(s))/cos Γ_(s)  (88)

[0521] If the intersection point P_(0CC) is expressed by the coordinate systems O₁, O_(q1), it can be expressed as follows.

P _(0CC)(u _(1p0) , −V _(cs1) , z _(1p0CC) ;O ₁)

P _(0CC)(q _(1p0C) , −R _(b10C) , z _(1p0CC) ; O _(q1))

z _(1p0CC) =−u _(c0cc) cos Γ_(s) +z _(cOCC) sin Γ_(s) −z _(1c0)  (89)

[0522] (3) Phase Angle of Tooth Surface C_(c)

[0523]FIG. 34 shows a relationship of a point of contact P_(wsCC) of a tooth surface C_(c)(g_(0CC)) at the rotation angle θ₁ (=0) to the design reference point P₀. When the rotation angle θ₁=0, the tooth surface C_(c) has rotated by a phase angle θ_(1wsC) to the point P₀, and the phase angle θ_(1wsCC) of the point P_(wsCC) to the point P_(0CC) can be obtained from the following expressions with respect to g_(0CC),

P _(0CC) P _(wsCC) =R _(b10C)θ_(1wsC) cos ψ_(b10CC) −z sin ψ_(b10CC)

θ_(1wsCC)=20_(1p)(P _(0C) P _(wsCC))/P _(g0CC)

P _(g0CC)=2πR _(b10C) cos ψ_(b10CC) /N ₁  (90)

[0524] where 2θ_(1p):the angular pitch of the pinion.

[0525] (4) Equation of Path of Contact g_(0CC)

[0526] The equations of the path of contact g_(0CC) to be determined finally by the modification described above can be expressed as follows in the coordinate systems O₁, O_(q1).

q ₁(θ₁)=R _(b10C)(θ₁+θ_(1wsCC))cos² ψ+q _(b10CC)

χ₁(θ₁)=χ_(10C)=π/2−φ_(10C)

u ₁(θ₁)=q ₁ cos χ_(10C) +R _(b10C) sin χ_(10C)

v ₁(θ₁)=q ₁ sin χ_(10C) −R _(b10C) cos χ_(10C)

z ₁(θ₁)=R _(b10C)(θ₁+θ_(1wsCC))cos ψ_(b10CC) sin ψ_(b10CC) +z _(1p0CC)  (91)

[0527] The normal n_(0C) of the tooth surface Cc passing the design reference point P₀ does not become a contact normal.

[0528] 9. Conjugate Large Gear Tooth Surface and Top Land

[0529] 9.1 Conjugate Large Gear Tooth Surface

[0530]FIG. 35 and FIG. 36 show an effective surface of action (FIG. 35) drawn by the pinion involute helicoidal tooth surface D determined in such a way as described above and a generated gear conjugate tooth surface D (FIG. 36). R_(1h) designates the radius of the face cylinder of pinion. The path of contact on which the contact ratio of the tooth surface D becomes maximum is located on the large end side far from the g_(0D), and the value thereof is about 2.1. Consequently, the tooth bearing of the tooth surface D must be formed on the large end side along the path of contact on which the contact ratio becomes maximum.

[0531] Similarly, FIG. 37 and FIG. 38 show an effective surface of action (FIG. 27) drawn by the pinion tooth surface C_(c) and a generated gear conjugate tooth surface C_(c) (FIG. 38). It is known that the effective surface of action and the large gear conjugate tooth surface C_(c) are realized within the zone (R_(2t)-R_(2h)) of the large gear given by the selected pinion tooth surface C_(c). The contact ratio along the path of contact is 0.9. Consequently, the tooth bearing of the tooth surface C_(c) cannot but be formed on the small end side for the use of the lengthwise engagement. In the tooth surface C_(c), the conditions of the fluctuation of a bearing load being zero is not satisfied.

[0532] 9.2 Large Gear Top Land

[0533]FIG. 39 shows a state of a tooth of a large gear viewed from the gear axis thereof, and draws lines of intersection of the aforesaid conjugate large gear tooth surfaces D, C_(c) with the planes of rotation of the large gear at Z_(2h)=0 (face surface), Z_(2h)=3, Z_(2h)=6. In the figure, the widths of two lines at each of Z_(2h)=0, 3, 6are large gear thicknesses. The thickness at the face surface Z_(2h)=0 (hatched zone in the figure) is the large gear face surface. Here, the ending of the line of intersection with Z_(2h)=0 at the point P₀ means that the tooth surface at the face surface does not exist from that point because φ_(n0D)≈φ_(n2z).

[0534] Furthermore, the fact that in the figure the lines of intersection of the aforesaid planes Z_(2h)=3, 6 with the tooth surface C_(c) do not extend to the left side of the action limit curve L_(3Acc) indicates that an undercut is occurred at the part. However, a tooth surface is realized in a large gear zone at the top part as it has been examined at paragraph 7.1.

[0535] Generally, a sharpened top is generated on the large end side of a large gear in a combination of a cylinder pinion and a disk gear. In the present embodiment, the top land becomes somewhat narrower to the large end, but a top land that is substantially allowable for practical use is realized. This fact is based on the following reason.

[0536] In the present embodiment, the paths of contact g_(0D), g_(0C) are both located at the vicinity of the limiting path g_(2z), and incline to the g_(2z) in the reverse directions mutually. Consequently, the base cylinder radii R_(b20D), R_(b20C) of the g_(0D) and the g_(0C) on the gear side are near to the base cylinder radius R_(b2z) of the g_(2z), and the difference between them is small. Then, by modification of the tooth surface C to the tooth surface C_(c) (point P_(0C) is changed to the point P_(0CC)), the difference becomes still smaller as a result.

[0537] If an arbitrary path of contact in a surface of action in the vicinity of the paths of contact g_(0D), g_(0C) drawn by an involute helicoid of a pinion is designated by g_(m), the inclination angle g_(m) of the arbitrary path of contact g_(m) can be expressed as follows by transforming the inclination angle g_(m)(φ_(1m), ψ_(b1m); O₁) given by the coordinate system O₁ to the inclination angle in the coordinate system O₂,

tan_(100 2m)=tan ψ_(b10)/cos φ_(1m)

sin ψ_(b2m)=−cos ψ_(b10) sin φ_(1m)  (92)

[0538] where Σ=π/2, ψ_(b1m)=ψ_(b10) (constant).

[0539] As a design example, in a case wherein the i₀ is large and the ψ₀ is also large (60°), the ψ_(b10) is large, and the changes of the inclination angle φ_(2m) of the path of contact is small as shown in FIGS. 28-30. Consequently, the changes of the φ_(b2m) becomes further smaller from the expressions (92).

[0540] On the other hand, because the gear tooth surface is the conjugate tooth surface of an involute helicoid, the following relationship is concluded.

R _(b2m) cos ψ_(b2m) =i ₀ R _(b10) cos ψ_(b10)  (93)

[0541] If the changes of the ψ_(2m) are small, the changes of the R_(2m) also becomes small from the expression (93). Consequently, the large gear tooth surfaces D, C_(c) can be considered as involute helicoids having base cylinders R_(b20D) and R_(b20C) whose cross sections of rotation are approximate involute curves. Because the difference between R_(b20D) and R_(b20C) is small, the two approximate involute curves are almost parallel with each other, and the top land of the large gear is almost constant from the small end to the large end.

[0542] By the selection of the design variables ψ₀, φ_(n0D), φ_(n0C) as described above, the undercut at the small end and the sharpening of the top, which are defects of a conventional face gear, are overcome, and it becomes possible to design an involute hypoid gear for power transmission.

[0543] Furthermore, the following points are clear as the guidelines of design of a hypoid gear having an involute helicoidal tooth surface.

[0544] (1) The radius R₂₀ of the design reference point P₀ is located at the center of the inner radius and the outer radius of the large gear, and the inclination angle ψ₀ of the plane S_(n) perpendicular to the relative velocity at the point P₀ is determined so as to substantially satisfy the following expressions.

R ₂₀=(R _(2t) +R _(2h))/2

ε₂₀=sin⁻¹(−v _(cs2) /R ₂₀)

ψ₀=±cos⁻¹(R _(2t) /R ₂₀)−ε₂₀

[0545] where

[0546] for + of the double sign:ordinal hypoid gear (ψ₀≧−ε₂₀)

[0547] for − of the double sign:face gear (ψ₀<−ε₂₀).

[0548] By the ψ₀ determined in this manner, the radius of the action limit curve of each path of contact constituting a surface of action becomes smaller than the radius R_(2t) in the large gear. That is, the action limit curve can be located on the outer of the face width, and thereby the whole of the face width can be used for the engagement of the gear.

[0549] (2) The line of intersection of the plane of rotation of large gear Z₂₀ passing the design reference point P₀ and the plane S_(n) is supposed to be a limiting path g_(2z). The inclination angle of the limiting path g_(2z) on the plane S_(n) is designated by g_(2z) (ψ₀, φ_(n2z); C_(s)). A normal (path of contact) g_(0D) of the tooth surface D passing the point P₀ is selected at a position near to the limiting path g₂z That is, if the inclination angle of the 90D on the plane S. is designated by g_(0D) (ψ₀, φ_(n0D); C_(s)), the φ_(n0D) is selected as follows.

φ_(n0D)≈φ_(n2z)(φ_(n0D)>φ_(n2z))

[0550] This condition meets the case where the contact of the tooth surface D at the point P₀ becomes a convexo-convex contact (ψ₀≧−ε₂₀) as the result of the selection of the ψ₀. On the other hand, in case of a convexo-concave contact (φ₀<−ε₂₀), a normal of the tooth surface C on the opposite side is selected as described above.

[0551] (3) If the inclination angle of the normal (path of contact) g_(0C) of the tooth surface C passing the point P₀ on the plane S_(n) is supposed to be designated by g_(0C) (ψ₀, φ_(n0C); C_(s)), φ_(n0C) can be selected as follows.

φ_(n0C)=φ_(n0D)−2φ_(n0R)

[0552] Here, the 2φ_(n0R) is the vertex angle of an equivalent rack, and is within a range of 30°-50°, being 38° or 40° ordinarily. By the selection of the φ_(n0D), φ_(n0C) in such a way mentioned above, a wide effective surface of action can be formed in the vicinity of the design reference point P₀. In other words, the radius of the action limit curve being a boundary of the effective surface of action can be made to be smaller than the radius R_(2t) in the large gear.

[0553] (4) The face surface of a gear (plane of rotation of the gear) is located on the outer of a base cylinder determined by the paths of contact g_(0D), g_(0C) determined as described in (2), (3). By use of an equivalent rack having the line of intersection (limiting path g_(t)) of the plane S_(n) and the plane S_(t) formed by the peripheral velocities of the design reference point P₀ as its reference line and the g_(0D) and the g_(0C) as its tooth surface normal, a tooth depth having given top lands of a pinion and a large gear and the face surface (cylinder) of the pinion are determined. The face surface of the gear is selected to be on the outer of the base cylinder radii R_(b10D), R_(b10C) of the pinion.

[0554] (5) An involute helicoid having tooth surface normals of the paths of contact g_(0D), g_(0c) is given to the pinion side or the large gear side, and further a mating surface is generated. The values for g_(0D) or g_(0C) are modified such that the tooth surface D and the tooth surface C on the pinion side have almost the same leads and the base cylinder radii to which the g_(0D) and the g_(0C) on the large gear side are tangent are almost the same. By the modification of the tooth surfaces D, C of the pinion to have the same leads, the top land of the pinion becomes constant in the axis direction. Furthermore, by the modification of the base cylinder radii on the large gear side, the top land of the gear also becomes almost the same in the radius direction.

[0555] In the hypoid gear design described above, a computer support design system (CAD system) shown in FIG. 40performs design support. The CAD system is provided with a computer 3 including a processor 1 and a memory 2, an input unit 4, an output unit 5 and an external memory 6. In the external memory 6, data are read from and written into a recording medium. A gear design program for implementing the gear design method mentioned above is recorded in the recording medium in advance. As the occasion demands, the program is read out from the recording medium to be executed by the computer 3.

[0556] The program, more concretely, executes operations in accordance with the design guides (1)-(5) of the hypoid gear described above. FIG. 41 shows the outline of the operation flow. At first, the radius R₂₀ of the design reference point P₀ and the inclination angle ψ₀ of the plane S_(n) are determined on the basis of requirement values of the design of a hypoid gear (S100). Next, the normal (path of contact) g_(0D) of the tooth surface D passing at the design reference point P₀ is determined from the limiting path g_(2z) (S102). Furthermore, the normal (path of contact) g_(0C) of the tooth surface C passing at the design reference point P₀ is determined (S104). Moreover, the face surface of the gear and the face surface of the pinion are determined on the basis of the paths of contact g_(0D), g_(0C) (S106). One of either the pinion side or the large gear side of the involute helicoid having the paths of contact g_(0D), g_(0C) c as its tooth surface normal is given, and the other side is then determined (S108). Whether the formed tooth surfaces C, D of the pinion have almost the same leads or not is then judged (S110). If the tooth surfaces C, D do not have almost the same leads, the system returns to the step S102 and obtains the path of contact again. Furthermore, whether the base cylinder radii contacting with the paths of contact g_(0D), g_(0C) of the formed large gear are almost the same to each other or not is judged (S112). If the base cylinder radii are not almost the same to each other, the system returns to the step S102, and the paths of contact are obtained again.

[0557] Table 1 shows an example of calculated specifications of a hypoid gear. TABLE 1 CYLINDER RADIUS FOR DESIGNING LARGE GEAR R₂₀ 77 (mm) INCLINATION ANGLE OF PLANE S_(n) ψ₀ (°) 60 Designed value in coordinate system C_(s) P₀ (u_(c0), 0, z_(c0); C_(s)) (mm) (13.96, 0, 75.00) SPECIFICATIONS OF EQUIVALENT RACK g_(2z) (ψ₀, Φ_(n2z); C_(s)) (°) (60.0, 11.93) g_(t) (ψ₀, Φ_(nt); C_(s)) (°) (60.0, 7.13) g_(0D) (ψ₀, Φ_(n0D); C_(s)) (°) (60.0, 11.93) g_(0C) (ψ₀, Φ_(n0C); C_(s)) (°) (60. 0, 11.93) GEAR ADDENDUM A_(d2) (mm) 0.0 NORMAL PITCH P_(g0D) (mm) 9.599 P_(g0C) (mm) 8.269 P_(gt) (mm) 9.667 WORKING DEPTH h_(k) (mm) 3.818 where t_(n) = 2 mm and C_(R) = 2 mm are supposed PHASE ANGLE OF TOOTH SURFACE C θ_(2wsC) (°) −3.13 SPECIFICATIONS OF TOOTH SURFACE C_(c) P_(0CC (u) _(c0CC), 0, z_(c0CC); C_(s)) (mm) (15.35, 0, 69.30) g_(0CC) (ψ_(0CC), Φ_(n0CC); C_(s)) (°) (62.30, 0, −21.60) PHASE ANGLE OF TOOTH SURFACE C_(c) θ_(1wsCC) (°) 6.37 SPECIFICATIONS OF PINION RADIUS OF CYLINDER TO BE DESIGNED R₁₀ (mm) 31.391 MAJOR DIAMETER R_(1h) (mm) 35.18 MINOR DIAMETER R_(1t) (mm) 29.39 TOOTH SURFACE WIDTH (mm) 28 LEAD (mm) 109.83 HELICAL ANGLE ON CYLINDER TO BE DESIGNED (°) 60.89 SPECIFICATIONS OF INVOLUTE HELICOID TOOTH SURFACE D TOOTH SURFACE C_(c) BASE CYLINDER 31.389 17.754 RADIUS (mm) HELICAL ANGLE (°) 60.89 45.44 THICKNESS IN RIGHT ANGLE DIRECTION TO AXIS OF CYLINDER TO BE DESIGNED 12.685 TOP THICKNESS 6.556 MAXIMUM CONTACT RATIO ALONG PATH OF CONTACT 2.10 0.88 TOTAL CONTACT 4.21 2.10 RATIO 

1. A method for designing a hypoid gear consisting of a pair of gears including a pinion and a large gear, either of said gears being a first gear having an involute helicoid as a tooth surface, the other of said gears being a second gear having a tooth surface conjugate to the former tooth surface, said method comprising the steps of: assigning to said gears (a) a stationary coordinate system in which one of three mutually orthogonal coordinate axes coincides with a rotation axis of the gear and one of other two coordinate axes coincides with a common perpendicular for the rotation axis of the gear and a rotation axis of a mating gear to be engaged with the gear, (b) a rotary coordinate system in which one of three mutually orthogonal coordinate axes coincides with the axis of said stationary coordinate system that coincides with the rotation axis of the gear among the three coordinate axes of said stationary coordinate system, said rotary coordinate system rotating about the coincided coordinate axis together with the gear, the other two coordinate axes of the three orthogonal axes coinciding with the other two axes of said stationary coordinate system respectively when a rotation angle of the gear is zero, and (c) a parameter coordinate system in which said stationary coordinate system is rotated and transformed about the rotation axis of the gear so that one of the other two coordinate axes of said stationary coordinate system becomes parallel with the plane of action of the gear, respectively; describing a path of contact of a pair of tooth surfaces of the gear and the mating gear which engage with each other during the rotation of the gears and an inclination angle of a common normal which is a normal at each point of contact for the pair of tooth surfaces respectively in terms of a first function, in which a rotation angle of the gear is used as a parameter, in said parameter coordinate system; describing the path of contact and the inclination angle of the common normal respectively in terms of a second function, in which a rotation angle of the gear is used as a parameter, based on the first function and a relationship between relative positions of said stationary coordinate system and said parameter coordinate system, in said stationary coordinate system; acquiring the path of contact and the inclination angle of the common normal in the stationary coordinate system, respectively, and acquiring a tooth profile by describing the path of contact and the inclination angle of the common normal, respectively, in terms of a third function, in which the rotation angle of the gear is used as a parameter, based on the second function and the relationship between the relative positions of said rotary coordinate system and said stationary coordinate system, in said rotary coordinate system; acquiring a surface of action for the pair of tooth surfaces having the tooth profile; acquiring action limit curves which are orthogonal projections of axes of the two gears on the surface of action, and acquiring a tip line of the second gear in the surface of action, based on the tooth surface of the second gear, and further acquiring an effective surface of action existing between the action limit curves and the tip line; and judging whether or note the effective surface of action exists over a whole face width of the gear.
 2. A hypoid gear design method according to claim 1, said method further comprising the step of: acquiring an angle between paths of contact for the tooth surface of a drive side of the first gear and the tooth surface of a coast side of the first gear such that the teeth of the first gear have an appropriate strength.
 3. A hypoid gear design method according to claim 2, said method further comprising the steps of: acquiring specifications of an equivalent rack including a tooth surface based on the path of contact of the respective tooth surfaces of the drive side and the coast side; and acquiring a distance of the respective tip lines of the tooth surface of the drive side and the tooth surface of the coast side of the second gear, based on the specifications of the equivalent rack, and judging whether the acquired distance is equal to or greater than a predetermined value.
 4. A hypoid gear design method according to claim 1, wherein at the acquiring of the pair of tooth surfaces a design reference point is set near a center of the face width of the gear, and when the effective surface of action is insufficient at a small end side of the face width of the gear, the design reference point is shifted toward the small end side of the face width of the gear, and the effective surface of action is acquired again.
 5. A hypoid gear design method according to claim 3, wherein at the acquiring of the pair of tooth surfaces a design reference point is set near a center of the face width of the gear, and when the distance of the tip line is insufficient at a large end side, the design reference point is shifted toward the large end side of the face width of the gear, and the effective surface of action is acquired again.
 6. A hypoid gear design method according to claim 3, wherein at the acquiring of the pair of tooth surfaces a design reference point is set near a center of the face width of the gear, and when the effective surface of action is insufficient at a small end side of the face width of the gear and the distance of the tip line is insufficient at a large end side, the face width of the gear is reduced.
 7. A program for executing a hypoid gear design method according to any one of claims 1-6 with a computer.
 8. A hypoid gear in which a tooth surface of one gear of a pair of gears is an involute helicoid, wherein, in said hypoid gear, a radius of a base circle of the gear having the involute helicoidal tooth surface differs at a drive side and a coast side.
 9. A hypoid gear according to claim 8, wherein leads of tooth surfaces on the drive side and the coast side of the gear provided with the involute helicoid are almost the same.
 10. A hypoid gear according to claim 8, wherein a ratio of an offset E being the shortest distance between each axis of a pinion and a gear constituting said hypoid gear and a radius R₂₀ at a design point of the gear (E/R₂₀) is larger than 0.25.
 11. A hypoid gear according to claim 8, a gear ratio i₀ thereof is within a range of 2.5 to
 5. 12. A hypoid gear according to claim 8, wherein a helical angle ψ₀ thereof is within a range of 35° to 70°. 